Stapling end effector configured to compensate for an uneven gap between a first jaw and a second jaw

ABSTRACT

A staple cartridge disclosed herein comprises a cartridge body and staples removably stored therein. The staple cartridge further comprises a longitudinal row of staple drivers movable between an unfired position and a fired position to drive the staples toward an anvil and a firing system movable toward a distal end of the cartridge body to sequentially move the staple drivers toward their fired positions. The staple drivers comprise a first staple driver comprising a first bottom drive surface and a first staple support surface, wherein a first driver distance is defined between the first bottom drive surface and the first staple support surface, and a second staple driver comprising a second bottom drive surface and a second staple support surface, wherein a second driver distance is defined between the second bottom drive surface and the second support surface which is different than the first driver distance.

BACKGROUND

The present invention relates to surgical instruments and, in variousembodiments, to surgical stapling and cutting instruments and staplecartridges for use therewith.

A stapling instrument can include a pair of cooperating elongate jawmembers, wherein each jaw member can be adapted to be inserted into apatient and positioned relative to tissue that is to be stapled and/orincised. In various embodiments, one of the jaw members can support astaple cartridge with at least two laterally spaced rows of staplescontained therein, and the other jaw member can support an anvil withstaple-forming pockets aligned with the rows of staples in the staplecartridge. Generally, the stapling instrument can further include apusher bar and a knife blade which are slidable relative to the jawmembers to sequentially eject the staples from the staple cartridge viacamming surfaces on the pusher bar and/or camming surfaces on a wedgesled that is pushed by the pusher bar. In at least one embodiment, thecamming surfaces can be configured to activate a plurality of stapledrivers carried by the cartridge and associated with the staples inorder to push the staples against the anvil and form laterally spacedrows of deformed staples in the tissue gripped between the jaw members.In at least one embodiment, the knife blade can trail the cammingsurfaces and cut the tissue along a line between the staple rows.

The foregoing discussion is intended only to illustrate various aspectsof the related art in the field of the invention at the time, and shouldnot be taken as a disavowal of claim scope.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a longitudinal cross-sectional view of an end effector of asurgical instrument system illustrated in an open, or unclamped,configuration which includes a staple cartridge, staples removablystored in the staple cartridge, and an anvil configured to deform thestaples;

FIG. 2 is a longitudinal cross-sectional view of the end effector ofFIG. 1 illustrated in a closed, or clamped, configuration andillustrating a firing member in a pre-fired position prior to firing thestaples;

FIG. 3 is a longitudinal cross-sectional view of the end effector ofFIG. 1 illustrating a firing member of the end effector in apartially-fired position;

FIG. 4 is a longitudinal cross-sectional view of the end effector ofFIG. 1 illustrating the firing member in a retracted position;

FIG. 5 is a longitudinal cross-sectional view of the end effector ofFIG. 1 illustrating the end effector in a re-opened configuration;

FIG. 6 is a perspective view of a surgical stapling system comprising anend effector in accordance with at least one embodiment;

FIG. 7 is a partial cross-sectional perspective view of the end effectorof FIG. 6;

FIG. 8 is a partial cross-sectional elevational view of the end effectorof FIG. 6 illustrating the end effector in an open, unfiredconfiguration;

FIG. 9 is another partial cross-sectional elevational view of the endeffector of FIG. 6 illustrating a closure system of the end effector inan open configuration and a firing system of the end effector in anunfired configuration;

FIG. 10 is a partial cross-sectional elevational view of the endeffector of FIG. 6 illustrating the closure system in a partially closedconfiguration and the firing system in an unfired configuration;

FIG. 11 is a partial cross-sectional elevational view of the endeffector of FIG. 6 illustrating the closure system in a fully closedconfiguration and the firing system in a partially fired configuration;

FIG. 12 is a partial cross-sectional elevational view of the endeffector of FIG. 6 illustrating the closure system in a fully closedconfiguration and the firing system in a fully fired configuration;

FIG. 13 is a partial cross-sectional elevational view of the endeffector of FIG. 6 illustrating the closure system in a fully closedconfiguration and the firing system in a fully retracted configuration;

FIG. 14 is a partial cross-sectional elevational view of the endeffector of FIG. 6 illustrating the closure system in the process ofbeing returned to an open configuration and the firing system in a fullyretracted configuration;

FIG. 15 is a partial cross-sectional elevational view of an end effectorcomprising a staple firing system configured to compensate for an unevengap between an anvil and a staple cartridge of the end effector inaccordance with at least one embodiment;

FIG. 16 is a longitudinal cross-sectional view of an end effector of asurgical instrument system illustrated in an open, or unclampedconfiguration which includes a staple cartridge, staples removablystored in the staple cartridge, and an anvil configured to deform thestaples;

FIG. 17 is a longitudinal cross-sectional view of a portion of the endeffector of FIG. 16 with a portion of the anvil shown in cross-sectionand illustrated in an open position with the closure nut thereof in abeginning position and with the firing nut shown in a starting pre-firedposition;

FIG. 18 is another longitudinal cross-sectional view of the end effectorof FIG. 17 with the anvil portion shown in full view;

FIG. 19 is another longitudinal cross-sectional view of a portion of theend effector of FIG. 17 with a portion of the anvil shown incross-section and with the closure nut in the “intermediate”fully-closed position and the firing nut in a pre-fired position locatedat the distal end of the neutral firing range;

FIG. 20 is another longitudinal cross-sectional view of a portion of theend effector of FIG. 19 with the anvil portion shown in full view;

FIG. 21 is another longitudinal cross-sectional view of a portion of theend effector of FIG. 19 with the firing nut located at an end positionafter the staples have been fired from the staple cartridge with aportion of the anvil shown in cross-section;

FIG. 22 is another longitudinal cross-sectional view of a portion of theend effector of FIG. 21 with the anvil portion shown in full view;

FIG. 23 is a partial cross-sectional top view of a portion of a shaftassembly of a surgical instrument with the actuator member thereof in anengaged configuration;

FIG. 24 is another partial cross-sectional elevational view of the shaftassembly of FIG. 23;

FIG. 25 is another partial cross-sectional top view of the shaftassembly of FIGS. 23 and 24 illustrating the locking system thereof in a“pre-lock configuration”;

FIG. 26 is a partial cross-sectional elevational view of the shaftassembly of FIG. 25;

FIG. 27 is another partial cross-sectional top view of the shaftassembly of FIGS. 23-26 with the actuator member in the disengagedconfiguration and the lock system in a locked configuration; and

FIG. 28 is a partial cross-sectional elevational view of the shaftassembly of FIG. 27.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following patentapplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. ______, entitled SURGICAL        INSTRUMENT WITH SELECTIVELY DISENGAGEABLE THREADED DRIVE        SYSTEMS; Attorney Docket No. END7554USNP/140479; and    -   U.S. patent application Ser. No. ______, entitled SURGICAL        INSTRUMENT WITH PROGRESSIVE ROTARY DRIVE SYSTEMS; Attorney        Docket No. END7560USNP/140485.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/640,746, entitled POWERED        SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE        LEVEL THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE        TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR        MULTIPLE TISSUE TYPES; Attorney Docket No. END7557USNP/140482;    -   U.S. patent application Ser. No. 14/640,935, entitled OVERLAID        MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE        TISSUE COMPRESSION;    -   U.S. patent application Ser. No. 14/640,831, entitled MONITORING        SPEED CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED        SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/640,859, entitled TIME        DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINE STABILITY,        CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES;    -   U.S. patent application Ser. No. 14/640,817, entitled        INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/640,844, entitled CONTROL        TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH        SELECT CONTROL PROCESSING FROM HANDLE;    -   U.S. patent application Ser. No. 14/640,837, entitled SMART        SENSORS WITH LOCAL SIGNAL PROCESSING;    -   U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FOR        DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A        SURGICAL STAPLER;    -   U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND        POWER COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT; and    -   U.S. patent application Ser. No. 14/640,780, entitled SURGICAL        INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL        INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION;    -   U.S. patent application Ser. No. 14/633,546, entitled SURGICAL        APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER        OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE        BAND;    -   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL        CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE        BATTERIES;    -   U.S. patent application Ser. No. 14/633,566, entitled CHARGING        SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A        BATTERY;    -   U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FOR        MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED;    -   U.S. patent application Ser. No. 14/633,542, entitled REINFORCED        BATTERY FOR A SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 14/633,548, entitled POWER        ADAPTER FOR A SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE        SURGICAL INSTRUMENT HANDLE;    -   U.S. patent application Ser. No. 14/633,541, entitled MODULAR        STAPLING ASSEMBLY; and    -   U.S. patent application Ser. No. 14/633,562, entitled SURGICAL        APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/574,478, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND        MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING;    -   U.S. patent application Ser. No. 14/574,483, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS;    -   U.S. patent application Ser. No. 14/575,139, entitled DRIVE        ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/575,148, entitled LOCKING        ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE        SURGICAL END EFFECTORS;    -   U.S. patent application Ser. No. 14/575,130, entitled SURGICAL        INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A        DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE;    -   U.S. patent application Ser. No. 14/575,143, entitled SURGICAL        INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS;    -   U.S. patent application Ser. No. 14/575,117, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING        BEAM SUPPORT ARRANGEMENTS;    -   U.S. patent application Ser. No. 14/575,154, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING        BEAM SUPPORT ARRANGEMENTS;    -   U.S. patent application Ser. No. 14/574,493, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM;        and    -   U.S. patent application Ser. No. 14/574,500, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 13/782,295, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR        SIGNAL COMMUNICATION, now U.S. Patent Application Publication        No. 2014/0246471;    -   U.S. patent application Ser. No. 13/782,323, entitled ROTARY        POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2014/0246472;    -   U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL        SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2014/0249557;    -   U.S. patent application Ser. No. 13/782,499, entitled        ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT,        now U.S. Patent Application Publication No. 2014/0246474;    -   U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE        PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Patent Application Publication No. 2014/0246478;    -   U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK        SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2014/0246477;    -   U.S. patent application Ser. No. 13/782,481, entitled SENSOR        STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now        U.S. Patent Application Publication No. 2014/0246479;    -   U.S. patent application Ser. No. 13/782,518, entitled CONTROL        METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT        PORTIONS, now U.S. Patent Application Publication No.        2014/0246475;    -   U.S. patent application Ser. No. 13/782,375, entitled ROTARY        POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM,        now U.S. Patent Application Publication No. 2014/0246473; and    -   U.S. patent application Ser. No. 13/782,536, entitled SURGICAL        INSTRUMENT SOFT STOP, now U.S. Patent Application Publication        No. 2014/0246476.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 13/803,097, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now        U.S. Patent Application Publication No. 2014/0263542;    -   U.S. patent application Ser. No. 13/803,193, entitled CONTROL        ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now        U.S. Patent Application Publication No. 2014/0263537;    -   U.S. patent application Ser. No. 13/803,053, entitled        INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL        INSTRUMENT, now U.S. Patent Application Publication No.        2014/0263564;    -   U.S. patent application Ser. No. 13/803,086, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION        LOCK, now U.S. Patent Application Publication No. 2014/0263541;    -   U.S. patent application Ser. No. 13/803,210, entitled SENSOR        ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2014/0263538;    -   U.S. patent application Ser. No. 13/803,148, entitled        MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0263554;    -   U.S. patent application Ser. No. 13/803,066, entitled DRIVE        SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2014/0263565;    -   U.S. patent application Ser. No. 13/803,117, entitled        ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2014/0263553;    -   U.S. patent application Ser. No. 13/803,130, entitled DRIVE        TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Patent Application Publication No. 2014/0263543; and    -   U.S. patent application Ser. No. 13/803,159, entitled METHOD AND        SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

-   -   U.S. patent application Ser. No. 14/200,111, entitled CONTROL        SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent Application        Publication No. 2014/0263539.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/226,106, entitled POWER        MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/226,099, entitled        STERILIZATION VERIFICATION CIRCUIT;    -   U.S. patent application Ser. No. 14/226,094, entitled        VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT;    -   U.S. patent application Ser. No. 14/226,117, entitled POWER        MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE        UP CONTROL;    -   U.S. patent application Ser. No. 14/226,075, entitled MODULAR        POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES;    -   U.S. patent application Ser. No. 14/226,093, entitled FEEDBACK        ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/226,116, entitled SURGICAL        INSTRUMENT UTILIZING SENSOR ADAPTATION;    -   U.S. patent application Ser. No. 14/226,071, entitled SURGICAL        INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR;    -   U.S. patent application Ser. No. 14/226,097, entitled SURGICAL        INSTRUMENT COMPRISING INTERACTIVE SYSTEMS;    -   U.S. patent application Ser. No. 14/226,126, entitled INTERFACE        SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/226,133, entitled MODULAR        SURGICAL INSTRUMENT SYSTEM;    -   U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS        AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT;    -   U.S. patent application Ser. No. 14/226,076, entitled POWER        MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE        PROTECTION;    -   U.S. patent application Ser. No. 14/226,111, entitled SURGICAL        STAPLING INSTRUMENT SYSTEM; and    -   U.S. patent application Ser. No. 14/226,125, entitled SURGICAL        INSTRUMENT COMPRISING A ROTATABLE SHAFT.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY        AND SENSORS FOR POWERED MEDICAL DEVICE;    -   U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT        WITH INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION;    -   U.S. patent application Ser. No. 14/478,908, entitled MONITORING        DEVICE DEGRADATION BASED ON COMPONENT EVALUATION;    -   U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE        SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR        INTERPRETATION;    -   U.S. patent application Ser. No. 14/479,110, entitled USE OF        POLARITY OF HALL MAGNET DETECTION TO DETECT MISLOADED CARTRIDGE;    -   U.S. patent application Ser. No. 14/479,098, entitled SMART        CARTRIDGE WAKE UP OPERATION AND DATA RETENTION;    -   U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE        MOTOR CONTROL FOR POWERED MEDICAL DEVICE; and    -   U.S. patent application Ser. No. 14/479,108, entitled LOCAL        DISPLAY OF TISSUE PARAMETER STABILIZATION.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/248,590, entitled MOTOR        DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now        U.S. Patent Application Publication No. 2014/0305987;    -   U.S. patent application Ser. No. 14/248,581, entitled SURGICAL        INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE        OPERATED FROM THE SAME ROTATABLE OUTPUT, now U.S. Patent        Application Publication No. 2014/0305989;    -   U.S. patent application Ser. No. 14/248,595, entitled SURGICAL        INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE        OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0305988;    -   U.S. patent application Ser. No. 14/248,588, entitled POWERED        LINEAR SURGICAL STAPLER, now U.S. Patent Application Publication        No. 2014/0309666;    -   U.S. patent application Ser. No. 14/248,591, entitled        TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S.        Patent Application Publication No. 2014/0305991;    -   U.S. patent application Ser. No. 14/248,584, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR        ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS,        now U.S. Patent Application Publication No. 2014/0305994;    -   U.S. patent application Ser. No. 14/248,587, entitled POWERED        SURGICAL STAPLER, now U.S. Patent Application Publication No.        2014/0309665;    -   U.S. patent application Ser. No. 14/248,586, entitled DRIVE        SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now        U.S. Patent Application Publication No. 2014/0305990; and    -   U.S. patent application Ser. No. 14/248,607, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION        ARRANGEMENTS, now U.S. Patent Application Publication No.        2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. Provisional Patent Application Ser. No. 61/812,365,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR;    -   U.S. Provisional Patent Application Ser. No. 61/812,376,        entitled LINEAR CUTTER WITH POWER;    -   U.S. Provisional Patent Application Ser. No. 61/812,382,        entitled LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;    -   U.S. Provisional Patent Application Ser. No. 61/812,385,        entitled SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION        MOTORS AND MOTOR CONTROL; and    -   U.S. Provisional Patent Application Ser. No. 61/812,372,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical”, “horizontal”, “up”, and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongated shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich first jaw is pivotable relative to the second jaw. The surgicalstapling system further comprises an articulation joint configured topermit the end effector to be rotated, or articulated, relative to theshaft. The end effector is rotatable about an articulation axisextending through the articulation joint. Other embodiments areenvisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIGS. 1-5 are longitudinal cross-sectional views of an end effector of asurgical instrument system. The views depict the end effector in an openposition prior to being placed onto tissue (FIG. 1), in a closedposition ready for firing (FIG. 2), during a firing action to deploystaples into the tissue (FIG. 3), after the firing action has beencompleted (FIG. 4), and in a re-opened position (FIG. 5) to release theend effector from the tissue. This surgical instrument system is similarin many respects to the surgical instrument system disclosed in U.S.Pat. No. 5,667,517, entitled ENDOSCOPIC SURGICAL SYSTEM WITH SENSINGMEANS, which issued on Sep. 16, 1997 to Michael Dawson Hooven. Theentire disclosure of U.S. Pat. No. 5,667,517 is incorporated byreference herein.

The end effector of FIGS. 1-5 includes a shaft housing 60 and an endeffector housing 70. The end effector housing 70 is connected to theshaft housing 60 in any suitable manner, such as by a press fit orultrasonic welding, for example. A rotatable shaft 61 extends throughthe shaft housing 60 and is operably coupled with an electric motor, forexample, which can rotate the shaft 61. A threaded rod 71 extendssubstantially the length of the end effector and is connected to therotatable shaft 61. The threaded rod 71 has a larger diameter portion 72adjacent the shaft 61 and a smaller diameter portion 73 for theremainder of the threaded rod 71. The end effector further includes astaple or staple cartridge portion 74 and an anvil portion 75. Thestaple cartridge portion 74 and the anvil portion 75 are pivotallyconnected to each other by the anvil pivot pin 76. Threadably mounted onthe larger diameter portion 72 of the threaded rod 71 is a closure nut77 and extending from that closure nut 77 is a closure pin 78 whichmoves in a closure slot 79 disposed in the pivotally mounted anvilportion 75 of the end effector. When the shaft 61 is rotated, thethreaded rod 71 is also rotated and, upon the rotation thereof in afirst direction, the closure nut 77 will move down the threaded rod 71and move the closure pin 78 in the closure slot 79 to close the anvilportion 75 against the staple portion 74 of the end effector.

Further to the above, the tissue to be treated or manipulated by the endeffector is placed between the anvil portion 75 and the staple cartridgeportion 74 of the end effector when the anvil portion 75 is in its openposition. Once the tissue has been suitably positioned between the anvilportion 75 and the staple cartridge portion 74, power is applied to theshaft 61 to rotate the shaft 61 and the threaded rod 71 and close theanvil portion 75. As can be appreciated, the amount of torque requiredto pivot the anvil portion 75 about the pivot pin 76 can be sensed and,as a result, the thickness of tissue between the anvil portion 75 andthe staple cartridge portion 74 can be determined. The surgicalinstrument system can further include a microprocessor, or controller,which can manipulate this information and inform the surgeon as towhether or not an appropriate amount of tissue is positioned between theanvil portion 75 and the staple cartridge portion 74 of the end effectorupon closing the anvil portion 75 or whether too much or too littletissue is positioned between the anvil portion 75 and the staplecartridge portion 74. The microprocessor can also be configured toindicate to the surgeon whether or not the end effector should bere-manipulated. When the electric motor rotating the shaft 61 is drivenby a constant voltage, for example, the force required to close the endeffector may be measured by monitoring the motor current. In variousinstances, the power delivered to the end effector may be controlled byvarying the motor voltage and/or current to achieve a constant motorspeed with varying load, for example. In certain instances, pulse widthmodulation and/or frequency modulation may be utilized to control theelectric motor.

The staple cartridge portion 74 comprises a removable staple cartridge80. The staple cartridge 80 can include any suitable number of staplerows, such as four rows of staples 81 or six rows of staples 81, forexample. The staple rows are parallel to one another and, in adjacentrows, are off-set with respect to one another. The staple cartridge 80is placed in the staple cartridge portion 74 so that it is opposite theanvil portion 75 and snaps into the staple cartridge portion 74 of theend effector as shown. As depicted in FIGS. 1-5, the smaller diameterportion 73 of the threaded rod 71 extends through the staple cartridge80. The staple cartridge 80 can include an opening defined in the bottomthereof which permits the staple cartridge 80 to be positioned over thethreaded rod 71 and seated into position in the staple cartridge portion74. Other embodiments are envisioned in which the threaded rod 71, or atleast a portion of the threaded rod 71, is part of the staple cartridge80. In such an embodiment, the threaded rod 71 can be operably coupledwith the drive shaft 61 when the staple cartridge 80 is seated in thestaple cartridge portion 74. Some embodiments are envisioned in whichthe staple cartridge 80 is not readily replaceable within the endeffector. In at least one such embodiment, the end effector, as a whole,may be replaceable.

Mounted on the threaded rod 71 is a knife member 82 and a driving wedgemember 83 which are interconnected. The interconnected knife member 82and wedge member 83 are threadably engaged with the smaller diameterportion 73 of the threaded rod 71 and are advanced distally when thethreaded rod 71 is rotated in the first direction, i.e., the samedirection in which the threaded rod 71 is rotated to close the anvilportion 75. The wedge member 83 precedes, or is positioned distally withrespect to, the knife member 82 as they move along the threaded rod 71.As the wedge member 83 moves down the threaded rod 71, the wedge member83 drives the staples 81 out of the cartridge 80 via staple drivers 84.The staple drivers 84 can comprise individual staple drivers or,alternatively, one or more of the staple drivers 84 can beinterconnected. The staples 81 pass through the tissue and are pushedagainst the anvil portion 75 to form the staples 81 in the tissue. Theknife member 82 following the driving wedge 83 cuts the tissue betweentwo adjacent rows of staples 81. The driving wedge 83 can be comprisedof two portions; that is, it has one wedge piece on one side of theknife member 82 to drive the staples 81 on a first side of the knifemember 82 and a like wedge piece on the opposite side of the knifemember 82 to drive the staples 81 on a second, or opposite, side of theknife member 82.

The staples 81 have the same unformed heights; however, it is envisionedthat the staples 81 can have different unformed heights. The staples 81have the same deformed heights; however, it is envisioned that thestaples 81 can have different deformed heights. The entire disclosure ofU.S. Patent Application Publication No. 2007/0131732, entitled SURGICALSTAPLING INSTRUMENTS INCLUDING A CARTRIDGE HAVING MULTIPLE STAPLE SIZES,now U.S. Pat. No. 7,398,908, which was filed on Nov. 3, 2006, isincorporated by reference herein. The entire disclosure of U.S. Pat. No.7,635,074, entitled STAPLE DRIVE ASSEMBLY, which issued on Dec. 22,2009, is incorporated by reference herein. The entire disclosures ofU.S. patent application Ser. No. 14/527,398, entitled STAPLE CARTRIDGESCOMPRISING DRIVER ARRANGEMENTS, which was filed on Oct. 29, 2014, andU.S. patent application Ser. No. 14/527,384, entitled CARTRIDGEASSEMBLIES FOR SURGICAL STAPLERS, which was filed on Oct. 29, 2014, areincorporated by reference herein.

When the anvil portion 75 is closed as shown in FIG. 2, the closure nut77 moves a stop member 85 forward so that the firing nut 86 on which theknife 82 and wedges 83 are disposed is moved forward and engages thethreads of the smaller diameter portion 73 of the threaded rod 71 tomove forward along the rod 71 and drive the staples 81 and cut thetissue. Concurrent with the closure nut 77 switching the stop member 85from its rearward facing configuration (FIG. 6) to its forward facingconfiguration (FIG. 7), the closure nut 77 runs off of, or disengagesfrom, the thread of the threaded portion 72. The firing nut 86 isbiased, using a suitable means, so as not to engage the thread of thethreaded portion 73 until the stop member 85 is activated, or pushedforward, as described above. Once the firing nut 86 has been moved toits most-forward position to drive and form all of the staples 81 andcut the tissue, the firing nut 86 engages a suitable contact 87 whichimmediately reverses the electric motor to rotate the rod in a second,or opposite direction, to retract the firing nut 86. In its fullyretracted position, referring now to FIG. 9, the firing nut 86 moves thestop member 85 rearwardly causing the closure nut 77 to becomere-engaged with the thread of the threaded portion 72. Concurrent withthe stop member 85 being pushed into its rearward facing configuration(FIG. 9), the firing nut 86 runs off of, or disengages from, the threadof the threaded portion 73. The continued rotation of the threaded rod71 in the second direction retracts the closure nut 77 and opens theanvil portion 75 of the end effector, as illustrated in FIG. 10.

Another configuration of the above-described embodiments would be tolocate contacts in a handle portion of the instrument, or a proximalhousing that is attached to a robotic surgical stapler, and use afollower nut on the rotating shaft 61 to monitor the position of theclosure nut 77 and/or the firing nut 86. The entire disclosure of U.S.patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.Patent Application Publication No. 2012/0298719, is incorporated byreference herein. Various information may be transmitted to and/or fromthe microprocessor of the surgical instrument system during theoperation thereof; for example, the movement of the stop member 85pushing the firing nut 86 onto the thread of the threaded portion 73and/or pushing the closure nut 77 onto the thread of the threadedportion 72 can be sensed. The most forward position of the wedges 83and/or knife member 82 may be sensed. The reversal of the motor may alsobe sensed. Furthermore, the presence of a staple cartridge 80 in thestaple cartridge portion 74 and/or the presence of staples 81 in thatcartridge 80 may also be sensed. All of this information may be fed backto the controller and stored and manipulated in the controller so thatthe surgeon using the instrument can receive information regarding thecondition of the surgical instrument system.

The surgical instrument systems disclosed herein can be utilized with anadjunct material, such as buttress material, for example. The adjunctmaterial can comprise one or more layers of material releasably attachedto the staple cartridge and/or the anvil. The entire disclosure of U.S.Patent Application Publication 2010/0012704, entitled SURGICAL STAPLINGAPPARATUS, which published on Jan. 21, 2010, now U.S. Pat. No.8,413,871, is incorporated by reference herein.

The surgical instrument system depicted in FIGS. 1-5 and described aboveis useful for its intended purpose; however, there are several aspectsof this surgical instrument system that can be improved. For instance,the closure nut 77 and the firing nut 86 are advanced sequentially.Stated another way, the closure nut 77 completes its entire closingstroke on the threaded portion 72 of the rod 71 before the firing nut 86begins its firing stroke on the threaded portion 73 of the rod 71. As aresult, the tissue clamping system must be fully clamped before thestaple firing system can be operated. Moreover, the firing nut 86 mustbe completely retracted before the closure nut 77 can be retracted. As aresult, the tissue clamping system cannot be unclamped immediately afterthe staples 81 have been fired; rather, the tissue clamping system isstuck in its clamped configuration until the firing system has beencompletely reset. In addition to the above, coordinating thedisengagement of the closure nut 77 from the thread of the threadedportion 72 at the same time that the closure nut 77 switches the stopmember 85 to its forward-facing configuration may require very precisetolerances. Similarly, coordinating the disengagement of the firing nut86 from the thread of the threaded portion 73 at the same time that thefiring nut 86 switches the stop member 85 to its rearward-facingconfiguration may also require very precise tolerances.

A surgical instrument system 150 is illustrated in FIGS. 6-14. Thesurgical instrument system 150 includes a shaft 160 and an end effector170 extending from the shaft 160. The shaft 160 extends from a housing152 which is configured to be attached to a robotic surgical system,such as the DAVINCI robotic surgical system manufactured by IntuitiveSurgical, Inc., for example. The entire disclosure of U.S. patentapplication Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTSWITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. PatentApplication Publication No. 2012/0298719 is incorporated by referenceherein. Alternatively, the shaft 160 can extend from a handle of asurgical instrument configured to be grasped and operated by a surgeon,for example. The entire disclosures of U.S. Pat. No. 7,143,923, entitledSURGICAL STAPLING INSTRUMENT HAVING A FIRING LOCKOUT FOR AN UNCLOSEDANVIL, which issued on Dec. 5, 2006; U.S. Pat. No. 7,044,352, SURGICALSTAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OFFIRING, which issued on May 16, 2006; U.S. Pat. No. 7,000,818, SURGICALSTAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS,which issued on Feb. 21, 2006; U.S. Pat. No. 6,988,649, SURGICALSTAPLING INSTRUMENT HAVING A SPENT CARTRIDGE LOCKOUT, which issued onJan. 24, 2006; and U.S. Pat. No. 6,978,921, SURGICAL STAPLING INSTRUMENTINCORPORATING AN E-BEAM FIRING MECHANISM, which issued on Dec. 27, 2005,are incorporated by reference herein. The shaft 160 comprises at leastone articulation joint, such as articulation joint 190, for example,which is configured to permit the end effector 170 to be articulatedabout at least one axis of rotation. Other embodiments are envisioned inwhich the shaft 160 does not comprise an articulation joint.

Referring primarily to FIG. 6, the end effector 170 comprises a staplecartridge portion 174 and an anvil portion 175. A staple cartridge 180is positioned in the staple cartridge portion 174. The staple cartridge180 is removable from the staple cartridge portion 174 such that it canbe readily replaced with another staple cartridge; however, otherembodiments are envisioned in which the staple cartridge 180 is notreadily replaceable. The anvil portion 175 is rotatable relative to thestaple cartridge portion 174 about pivot pins 176 extending from theanvil portion 175. Alternative embodiments are envisioned in which thestaple cartridge portion 174 is rotatable relative to the anvil portion175. The anvil 175 is rotatable between an open position (FIGS. 6-9) anda closed position (FIGS. 10-13) by a closure drive as described ingreater detail further below. Staples, such as staples 81, for example,are removably stored in the staple cartridge 180 and can be ejected fromthe staple cartridge 180 by a firing drive and deformed against theanvil 175, as also described in greater detail further below.

Referring primarily to FIGS. 7-9, the shaft 160 includes a rotatableinput shaft 161. As described in greater detail further below, the inputshaft 161 is utilized to operate the closing drive and the firing drive.The input shaft 161 is rotatably mounted in the shaft 160 by one or morebearings and comprises a threaded portion 172. The closure drivecomprises a closure nut 177 which includes a threaded aperture 162defined therein. The closure nut 177 further comprises closure pins 178extending from opposite sides thereof which are slidably positioned inclosure slots 179 defined in opposite sides of the anvil portion 175.

The threaded aperture 162 of the closure nut 177 is threadably engagedwith the threaded portion 172 of the input shaft 161 such that, when theinput shaft 161 is rotated in a first direction, the closure nut 177 isdisplaced distally toward the end of the end effector 170 and, when theinput shaft 161 is rotated in a second, or opposite, direction, theclosure nut 177 is displaced proximally toward the housing 152, asillustrated in FIG. 10. The interaction between the closure pins 178 ofthe closure nut 177 and the sidewalls of the closure slots 179 preventthe closure nut 177 from rotating with the input shaft 161 and, as aresult, the rotational motion of the input shaft 161 is converted tolongitudinal translation of the closure nut 177.

In use, the closure nut 177 is advanced distally by the input shaft 161to move the anvil portion 175 between an open position (FIGS. 6-9) and aclosed position (FIGS. 11-13). In such instances, the closure pins 178engage the bottom sidewalls of the closure slot 179 and cam the anvil175 toward the staple cartridge 180, as illustrated in FIG. 10.Similarly, referring to FIG. 14, the closure nut 177 is advancedproximally by the input shaft 161 to move the anvil portion 175 betweena closed position and an open position. In such instances, the closurepins 178 engage the top sidewalls of the closure slot 179 and cam theanvil 175 away from the staple cartridge 180.

The input shaft 161 further comprises a distal gear 165 fixedly mountedto the distal end thereof. When the input shaft 161 is rotated in thefirst direction, the distal gear 165 rotates in the first direction and,when the input shaft 161 is rotated in the second direction, the distalgear 165 rotates in the second direction. The firing drive of the endeffector 170 comprises a rotatable firing shaft 171 which is rotatablymounted in the staple cartridge portion 174 by one or more bearings,such as bearing 163, for example. The firing shaft 171 comprises aproximal gear 185 and a threaded portion 173. The proximal gear 185 ofthe firing shaft 171 is meshingly engaged with the distal gear 165 ofthe input shaft 161 such that the input shaft 161 can drive the firingshaft 171 when the input shaft 161 is rotated. The proximal gear 185 isslidably mounted to the firing shaft 171. More specifically, the firingshaft 171 comprises a splined portion 168 and the proximal gear 185includes a splined aperture 169 extending therethrough which is slidablycoupled to the splined shaft portion 168. As a result, the proximal gear185 can rotate the firing shaft 171 about a longitudinal axis and, inaddition, slide longitudinally along the longitudinal axis, as describedin greater detail below.

The firing drive further comprises a firing nut 186 which includes athreaded aperture 189 defined therein which is threadably engageablewith the threaded portion 173 of the shaft 171. The firing nut 186further comprises wedges 183 defined thereon which are configured toslide under the staple drivers 84 and lift the staples 81 toward theanvil portion 175 to staple tissue positioned between the staplecartridge 180 and the anvil portion 175. The firing nut 186 alsocomprises a cutting member 182 defined thereon which is configured toincise the stapled tissue. When the firing nut 186 is threadably engagedwith the shaft 171 and the input shaft 161 is rotated in the firstdirection, the firing nut 186 is displaced distally toward the end ofthe end effector 170 to eject the staples 81 from the staple cartridge180 and incise the tissue. When the firing nut 186 is threadably engagedwith the threaded portion 173 of the shaft 171 and the input shaft 161is rotated in the second direction, the firing nut 186 is displacedproximally toward the housing 152 to retract the wedges 183 and thecutting member 182 to their unfired position.

The above being understood, the surgical instrument system 150 comprisesa system for switching between a clamping operating mode and a staplefiring operating mode that is an improvement over the switching systemdisclosed in connection with the surgical instrument system of FIGS.1-5. Referring again to FIGS. 7-9, the closure nut 177 is movable from aproximal position to a distal position during a clamping stroke in orderto move the anvil portion 175 from its open position to its closedposition. When the closure nut 177 is in its proximal position, theclosure nut 177 is threadably engaged with the threads 172 defined onthe input shaft 171. The closure system can comprise a biasing member,such as spring 164, for example, which is configured to bias the threads162 of the closure nut 177 into engagement with, or maintain theirengagement with, the threads 172 of the input shaft 171. The spring 164is positioned intermediate the closure nut 177 and a shoulder 166defined on the shaft 171.

As a result of the above, the initial rotation of the input shaft 161 inthe first direction can immediately displace the closure nut 177distally to begin closing the anvil portion 175. Moreover, if the inputshaft 161 is inadvertently driven in the second direction when theclosure nut 177 is in its proximal position, the closure nut 177 maymove proximally and become disengaged from the threads 172 and enterinto an idle condition. The spring 164, however, can maintain thethreads 162 of the closure nut 177 in close proximity to the threads 172of the input shaft 161 such that, when the input shaft 161 is rotated inthe first direction, the threads 162 can catch the threads 172 and theclosure nut 177 can be pulled distally to close the anvil portion 175.

Notably, further to the above, the rotation of the input shaft 161 beingutilized to initiate the clamping stroke of the closure nut 177 is beingtransferred to the firing shaft 171 via the meshed gears 165 and 185.This rotation of the firing shaft 171 does not drive the firing nut 186distally as the firing nut 186, at this point in the operation of thesurgical instrument system 150, is not threadably engaged with thethreads 173 of the firing shaft 171. Rather, the firing nut 185 issitting in an idle position and the firing shaft 171 is rotating withinthe threaded aperture 169 defined in the firing nut 185. As discussed ingreater detail below, the firing nut 185 is pushed onto the threads 173by the closure nut 177 during a later portion of its clamping stroke.

Referring primarily now to FIG. 9, the closure nut 177 further comprisesa distally-extending switch arm 184. When the closure nut 177 is in itsproximal position, as illustrated in FIG. 9, the switch arm 184 is notin contact with the slidable proximal gear 185. During the distalmovement of the closure nut 177, the switch arm 184 contacts theproximal gear 185, as illustrated in FIG. 10. As can be seen in FIG. 10,the anvil portion 175 has not yet reached its fully-closed position whenthe switch arm 184 initially makes contact with the proximal gear 185.Thus, the closure nut 177 engages the proximal gear 185 prior tocompleting its clamping stroke. As the closure nut 177 is moved furtherdistally to complete its clamping stroke, the closure nut 177 displacesthe proximal gear 185 distally along the splined portion 168 of thefiring shaft 171. The distal displacement of the proximal gear 185displaces a push spring 181, which is positioned intermediate theproximal gear 185 and the firing nut 186, distally. Moreover, the distaldisplacement of the push spring 181 displaces the firing nut 186distally and into engagement with the threads 173. The threads 189 ofthe firing nut 186 comprise a distal-most thread 188 which can initiatethe threaded engagement between the firing nut 186 and the firing shaft171.

Upon comparing FIGS. 10 and 11, it can be appreciated that the spring181 can become compressed when it is being utilized to push the firingnut 186 distally as described above. In such instances, the pushingforce between the proximal gear 185 and the firing nut 186 can increaseas the proximal gear 185 is moved distally toward the firing nut 186. Inat least one instance, the displacement of the proximal gear 185 can belinearly proportional to the force that the spring 181 applies to thefiring nut 186. The force applied to the firing nut 186 by the spring181 can increase until the threads 189 of the firing nut 186 catch onthe threads 173 and, as a result, the firing nut 186 is pushed distallyby the firing shaft 171. Once the firing nut 186 is threadably engagedwith the threads 173, the firing nut 186 can pull away from the spring181, as illustrated in FIG. 12.

As a result of the above, the clamping operating mode can initiate thefiring operating mode before the clamping operating mode has beencompleted. In at least one instance, it may be desirable to initiate thestaple firing operating mode toward the end of the clamping operatingmode such that the staples 81 are not fired until the anvil portion 175has been at least suitably positioned. Moreover, the surgical instrumentsystem 150 can comprise a sensor system, for example, configured todetect when the staple firing operating mode has been initiated, or isabout to be initiated, and pause the electric motor which is driving theinput shaft 161. Such a sensor system can be configured to detect theposition of the closure nut 177, the firing nut 186, the proximal gear185, and/or the spring 181, for example. In at least one such instance,the electric motor can be paused to allow the surgeon to assess whetherthey want to proceed with firing the staples into the tissue or re-openthe anvil portion 175 to reposition the end effector 170. In at leastone instance, the surgeon can be provided with two switches toselectively operate—a first button which will re-start the electricmotor and proceed with the firing stroke or a second button which willreverse the electric motor to re-open the anvil portion 175, forexample. The first button can be green, for example, and the secondbutton can be red, for example. The first button can include indiciasuch as “GO FORWARD” thereon while the second button can have otherindicia such as “GO BACK” thereon, for example. Such switches can bepositioned on a remote control console and/or the handle of the surgicalinstrument, depending on the circumstances.

After the advancement of the closure nut 177 has initiated the firingoperating mode by pushing the firing nut 186 onto the thread 173 of thefiring shaft 171, as described above, the closure nut 177 will continueto move through its clamping stroke along the thread 172 of the inputshaft 161 until the closure nut 177 runs off of the thread 172 andbecomes operably disengaged from the input shaft 161. At such point, theanvil portion 175 will be in its fully closed position. Moreover, atsuch point, the closure nut 177 will be in an idle condition and thecontinued rotation of the input shaft 161 to operate the staple firingsystem will not advance the closure nut 177.

As described above, the firing nut 186 is advanced distally to eject thestaples 81 from the staple cartridge 180. The firing nut 186 can beadvanced to the distal end of the end effector 170 to complete a firingstroke, as illustrated in FIG. 12. The thread 173 on the firing shaft171 can be configured such that the firing nut 186 remains threadablyengaged with the firing shaft 171 when the firing nut 186 reaches theend of its firing stroke. In at least one such instance, the firing nut186, the wedges 183, and/or the cutting member 182 can change the stateof a switch 87 positioned at the distal end of the end effector 170 whenthe firing nut 186 reaches the end of its firing stroke. The switch 87is in communication with the controller of the surgical instrumentsystem 150 which can reverse the direction of the electric motor torotate the input shaft 161 in its second direction when the state of theswitch 87 is reversed. When the input shaft 161 is rotated in its seconddirection, the firing nut 186 is retracted toward its unfired position.In addition to or in lieu of the above, the surgical instrument 150 caninclude a switch which can be actuated by the surgeon to stop and/orreverse the direction of the electric motor.

Further to the above, referring now to FIG. 12, the firing nut 186 isretracted back to its unfired position to reset the firing system whenthe electric motor is operated in the second direction. As the firingnut 186 is being retracted, referring now to FIG. 13, the firing nut 186comes into contact with the spring 181 and pushes the spring 181proximally. The firing nut 186 contacts the spring 181 before the firingnut 186 runs off of, or disengages from, the thread 173. As the firingnut 186 pushes the spring 181 proximally, the spring 181 pushes theproximal gear 185 and the closure nut 177 proximally such that theclosure nut 177 threadably re-engages the thread 172 of the input shaft161, as illustrated in FIG. 13. The threaded aperture 162 of the closurenut 177 comprises a proximal thread 167 which catches the thread 172 toinitiate the threaded engagement between the closure nut 177 and theinput shaft 161. Once the closure nut 177 has been threadably re-engagedwith the thread 172, the continued rotation of the input shaft 161 inthe second direction moves the closure nut 177 proximally in order tocam the anvil portion 175 back into its open position and, as a result,reset the clamping system. Concurrently, the continued rotation of theinput shaft 161 in the second direction can cause the firing nut 186 tobe run off of, or become disengaged from, the threads 173 of the firingshaft 171. Once the firing nut 186 has become operably disengaged fromthe firing shaft 171, the firing system has been reset.

In use, the anvil portion 175 can be rotated away from its fully clampedposition to release the tissue captured between the anvil portion 175and the staple cartridge 180. Moreover, the anvil portion 175 may bemoved between its open position and its closed position to clamp andrelease tissue, as needed, and/or to position the anvil portion 175relative to the staple cartridge 180 such that the end effector 170 canbe inserted into a patient through a trocar, for example. The pausefeature described above can allow the surgical instrument system 150 tobe operated in a first operating range to open and close the anvilportion 175 without firing the staples in the staple cartridge 180and/or incising the tissue.

In addition to the aspects of the surgical instrument system of FIGS.1-5 discussed above, the closure nut 77 engages the anvil portion 75 atthe proximal end thereof and, as a result, the closure nut 77 may not beable to push the distal end of the anvil portion 75 into itsfully-closed position; moreover, the firing nut 86 does not include acamming member which can pull the distal end of the anvil portion 75into its fully-closed position. As such, the tissue gap between thedistal ends of the anvil portion 75 and the staple cartridge 80 may belarger than the tissue gap between the proximal ends of the anvilportion 75 and the staple cartridge 80 which can result in the distalstaples not being formed to the correct, or an at least suitable, formedheight. Improvements to this arrangement are discussed further below.

An end effector 270 of a surgical instrument system 250 is illustratedin FIG. 15. The end effector 270 comprises a staple cartridge portion274 and an anvil portion 275. The end effector 270 further comprises astaple cartridge 280 positioned in the staple cartridge portion 274.Similar to the above, the staple cartridge 280 is readily removable fromthe staple cartridge portion 274 and readily replaceable with anotherstaple cartridge. Other embodiments are envisioned in which the staplecartridge 280 is not readily removable from the staple cartridge portion274. The anvil portion 275 is rotatable relative to the staple cartridge280 between an open position and a closed position to compress tissue Ttherebetween. Other embodiments are envisioned in which the staplecartridge portion 274 is rotatable relative to the anvil portion 275. Ineither event, the end effector 270 is movable between an openconfiguration and a closed configuration in any suitable manner. In atleast one instance, the end effector 270 is moved from its openconfiguration to its closed configuration by cams 256 and 257 extendingfrom the firing nut 286. More specifically, the cam 257 is configured toenter a longitudinal cam slot 258 defined in the anvil portion 275 andthe cam 256 is configured to engage the staple cartridge portion 274and/or the staple cartridge 280 and co-operatively position the anvilportion 275 relative to the staple cartridge 280 when the firing nut 286is advanced distally. In other embodiments, the firing nut 286 does notcomprise cams to move the end effector 270 between its openconfiguration and its closed configuration. In at least one suchinstance, the end effector comprises a closing system which is separateand distinct from the staple firing system of the end effector. Theexamples provided herein are adaptable to both embodiments.

The staple cartridge 280 comprises a deck 291 configured to supporttissue thereon and a plurality of staple cavities 253 defined in thedeck 291. Staples 81, for example, are removably stored in the staplecavities 253. Each staple 81 comprises the same configuration. Forinstance, each staple 81 can comprise a U-shaped configuration or,alternatively, a V-shaped configuration, for example. A staple having aU-shaped configuration comprises a base and two legs extending from thebase which extend in parallel directions to one another. A staple havinga V-shaped configuration comprises a base and two legs extending fromthe base which extend in non-parallel directions to one another. Eachstaple 81 stored in the staple cartridge 280 is defined by the sameunformed height. The unformed height of a staple 81 is the overallheight of the staple measured from a plane including the bottom surfaceof its base to a plane including the tips of its legs. The staples 81can have an unformed height of 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, or 4.0mm, for example. The staple cartridge 280 further comprises a pluralityof staple drivers 284 a-284 g positioned in the staple cavities 253which support the staples 81 in the staple cavities 253. The firing nut286 comprises wedge surfaces 283 defined thereon which are configured toslide underneath the staple drivers 284 a-284 g and sequentially liftthe staple drivers 284 a-284 g, and the staples 81 supported thereon,toward the anvil portion 275. Each staple driver 284 a-284 g comprises aramp surface 281 defined on the bottom surface thereof which is engagedby the wedge surfaces 283 as the firing nut 286 is advanced distally.The anvil portion 275 comprises a plurality of staple forming pockets251 defined therein which are configured to deform the staples 81 asthey are ejected from the staple cavities 253.

Further to the above, the anvil portion 275 further comprises a tissuecompression surface 292 defined thereon which is configured to compresstissue against the cartridge deck 291 when the anvil portion 275 ismoved into its fully closed position. When the anvil portion 275 is inits fully closed position, it may be desirable for the anvil compressionsurface 292 to be parallel to the cartridge deck 291. In such aposition, the gap, i.e., tissue gap, between the anvil compressionsurface 292 and the cartridge deck 291 is constant along thelongitudinal length of the end effector 270. Stated another way, thetissue gap over the proximal-most staple cavity, i.e., tissue gap 255 a,is the same as the tissue gap over the distal-most staple cavity, i.e.,tissue gap 255 g, when the anvil portion 275 is parallel to the staplecartridge 280. Such a parallel position of the anvil portion 275,however, may not always be achievable in some instances. In certaininstances, the tissue T positioned between the anvil compression surface292 and the cartridge deck 291 may be thick and the anvil portion 275may not reach a parallel position when the anvil portion 275 reaches itsfinal, or fully-clamped, position. Moreover, in some instances, thedistal end 259 of the anvil portion 275 may deflect or bend upwardlywhen the end effector 270 is clamped onto thick tissue, for example. Ineither event, as illustrated in FIG. 15, the distal end 259 of the anvilportion 275 can be positioned further away from the cartridge deck 291than the proximal end 258. In such instances, as a result, the tissuegap over the distal-most staple cavity, i.e., tissue gap 255 g, islarger than the tissue gap over the proximal-most staple cavity, i.e.,tissue gap 255 a.

The firing nut 286 comprises a cutting surface, such as knife 282, forexample, configured to transect the tissue positioned intermediate thetissue compression surface 292 and the cartridge deck 291 as the firingnut 286 is advanced distally to drive the staples 81 toward the anvilportion 275, as described above.

Further to the above, each staple 81 is formed within a forming gap. Theforming gap for a staple 81 is the distance between a support surface onthe staple driver supporting the staple 81, such as support surfaces 244on staple drivers 284 a-284 g, for example, and the correspondingforming pocket 251 defined in the anvil portion 254 when the stapledriver has reached its fully-fired position. The staple driver reachesits fully-fired position when the crest, or apex, of the wedges 283passes under the bottom surface of the staple driver. The apex of thewedges 283 is defined by an apex height 243. As the firing nut 286 isadvanced distally, the crest of the wedges 283 sequentially passes underthe staple drivers 284 a-284 g to sequentially eject and deform thestaples 81. During the initial portion of the firing nut 286progression, the wedges 283 lift the drivers 284 a toward the anvilportion 275. As the wedges 283 are moving the drivers 284 a to theirfully-fired positions, the wedges 283 begin to lift the drivers 284 btoward the anvil portion 275. As the wedges 283 are moving the drivers284 b to their fully-fired positions, the wedges 283 begin to lift thedrivers 284 c toward the anvil portion 275, and so forth. In alternativeembodiments, the wedges 283 may not begin to lift the drivers 284 buntil after the drivers 284 a have been lifted to their fully-firedpositions and, similarly, may not begin to lift the drivers 284 c untilafter the drivers 284 b have been lifted to their fully-fired positions,and so forth.

As discussed above, the forming gap for a staple 81 is defined betweenthe support surface 244 of the driver supporting the staple 81 and theforming pocket 251 positioned opposite the staple 81 when driver hasreached its fully-fired position. Referring to FIG. 15, a forming gapdistance 254 a is defined between the support surface 244 of the stapledrivers 284 a and the forming pockets 251 positioned opposite the stapledrivers 284 a. Similarly, a forming gap distance 254 g is definedbetween the support surface 244 of the staple drivers 284 g and theforming pockets 251 positioned opposite the staple drivers 284 g. Thereader should note, however, that the forming gap distances 254 a and254 g depicted in FIG. 15 do not represent the fully-fired positions ofthe staple drivers 284 a and 284 g. In fact, the staple drivers 284 aand 284 g are illustrated in unfired positions in FIG. 15. Thus, itshould be appreciated that the distances 254 a and 254 g will shorten asthe staple drivers 284 a and 284 g are lifted toward the anvil portion275.

As discussed above, the orientation of the anvil portion 275 can affectthe tissue gap between the staple cartridge 280 and anvil portion 275.The orientation of the anvil portion 275 can also affect the forminggaps for the staples 81 within the end effector 270. When the distal end259 of the anvil portion 275 is positioned further away from the staplecartridge 280 than the proximal end 258, as illustrated in FIG. 15, theforming gaps for the staples 81 at the distal end of the end effector270 may be larger than the forming gaps for the staples 81 at theproximal end of the end effector 270, absent some compensatory measure.If such a compensatory measure is not undertaken, the distal staples 81will be formed to a different height than the proximal staples 81. In atleast one such instance, the staples 81 may be formed within a heightrange including the tallest formed staple at the distal end of the endeffector 270 and the shortest formed staple at the proximal end of theend effector 270. In some instances, such a formed height range of thestaples 81 can be suitable, especially if the gradient amongst theformed staple heights is small. In other instances, the proximal staples81 may be deformed to a suitable height while the distal staples 81 maynot be deformed to a suitable height.

The end effector 270 is configured to compensate for instances where theanvil portion 275 is not parallel to the staple cartridge 280. Statedanother way, the end effector 270 is configured such that there islittle, if any, difference in the forming gaps for the staples 81 whenthe anvil portion 275 has not been closed to a parallel positionrelative to the deck 291 of the staple cartridge 280. To achieve thisresult, the support surfaces 244 of the staple drivers 284 a-284 g canbe lifted to different heights in a manner which corresponds to theorientation of the anvil portion 275. For instance, the support surfaces244 of the staple drivers 284 a are lifted to a first height relative tothe cartridge deck 291 and the support surfaces 244 of the stapledrivers 284 b are lifted to a second height relative to the cartridgedeck 291 which is greater than the first height. Similarly, the supportsurfaces 244 of the staple drivers 284 c are lifted to a third heightrelative to the cartridge deck 291 which is greater than the secondheight. The arrangement of the first height, the second height, and thethird height is consistent with an angled anvil portion 275. Thisarrangement further includes the support surfaces 244 of the stapledrivers 248 d which are lifted to a fourth height that is greater thanthe third height, the support surfaces 244 of the staple drivers 248 ewhich are lifted to a fifth height that is greater than the fourthheight, the support surfaces 244 of the staple drivers 248 f which arelifted to a sixth height that is greater than the fifth height, and thesupport surfaces 244 of the staple drivers 248 g which are lifted to aseventh height that is greater than the sixth height, for example. Thesupport surfaces 244 extend above the cartridge deck 291 when the stapledrivers 284 a-284 g are in their fully-fired positions; however,alternative embodiments are envisioned where some of the supportsurfaces 244 or all of the support surfaces 244 may not extend above thedeck 291.

As discussed above, the staple drivers 284 a-284 g are lifted todifferent heights. The first lift height of the support surfaces 244 isequal to the sum of the apex height 243 of the wedges 283 and the driverheight 241 a of the staple drivers 284 a. Similarly, the second liftheight of the support surfaces 244 is equal to the sum of the apexheight 243 of the wedges 283 and the driver height 241 b of the stapledrivers 284 b. While the apex height 243 of the wedges 283 is the samefor the first lift height and the second lift height, the driver height241 a is shorter than the driver height 241 b and, as a result, thefirst lift height is shorter than the second lift height. Similarly, thethird lift height of the support surfaces 244 is equal to the sum of theapex height 243 of the wedges 283 and the driver height 241 c of thestaple drivers 284 c, which is taller than the driver height 241 b ofthe staple drivers 284 b. Along these lines, the driver height 241 d ofthe staple drivers 284 d is taller than the driver height 241 c of thestaple drivers 284 c, the driver height 241 e of the staple drivers 284e is taller than the driver height 241 d of the staple drivers 284 d,the driver height 241 f of the staple drivers 284 f is taller than thedriver height 241 e of the staple drivers 284 e, and the driver height241 g of the staple drivers 284 g is taller than the driver height 241 fof the staple drivers 284 f.

Each of the staple support surfaces 244 comprises a trough, or groove,defined in the top of a driver 284 a-284 g. Each trough is configured toreceive the base of a staple 81. The troughs are configured to closelyreceive the bases of the staples 81 such that there is little, if any,relative lateral movement between the staple bases and the supportsurfaces 244. Further to the above, the forming distances for thestaples 81 is measured from the bottom of the troughs to the top of thecorresponding forming pockets 251 defined in the anvil portion 275. Eachtrough comprises a substantially U-shaped, or rounded bottom,configuration; however, any suitable configuration can be used, such asa V-shaped, or angled bottom, for example. In either event, each troughcan comprise a cradle for supporting a staple 81.

As discussed above, the staple support surfaces 244 of the stapledrivers 284 a-284 g are lifted to different heights in order toeliminate, or at least mitigate, differences in the forming gaps for thestaples 81 between the staple support surfaces 244 and the anvil formingpockets 251. In certain embodiments, it is desirable for all of thestaples of the staple cartridge 280 to be formed to the same, or atleast substantially the same, formed height. In other embodiments, it isdesirable to form all of the staples in a first longitudinal row to afirst formed height and all of the staples in a second longitudinal rowto a second formed height which is different than the first formedheight. The examples provided above can be adapted to such embodiments.For instance, a first set of staple drivers having a first range ofdriver heights can be used to deploy a first longitudinal row of staplesand a second set of staple drivers having a second range of driverheights can be used to deploy a second longitudinal row of stapleswherein the second range of driver heights is different than the firstrange of driver heights. In at least one such instance, the second rangeof driver heights can be taller than the first range of driver heights.In certain embodiments, the first set of staple drivers are notconnected to the second set of staple drivers; however, embodiments areenvisioned in which a driver from the first set of staple drivers isconnected to a driver from the second set of staple drivers. In at leastone instance, two or more drivers within the same longitudinal row canbe connected to each other.

Further to the above, embodiments are envisioned which comprise three ormore longitudinal rows of staples which are formed to different formedheights utilizing different forming gaps. In at least one embodiment,the forming gap for the first row of staples is at least partiallydetermined by a first wedge 283, the forming gap for the second row ofstaples is at least partially determined by a second wedge 283, and theforming gap for the third row of staples is at least partiallydetermined by a third wedge 283. In such an embodiment, the apex height243 of the first wedge 283 is different than the apex height 243 of thesecond wedge 283. Similarly, the apex height 243 of the third wedge 283is different than the apex height 243 of the first wedge 283 and thesecond wedge 283.

In various instances, the staples in a first longitudinal row of staplescan have a first undeformed height and the staples in a secondlongitudinal row of staples can have a second undeformed height which isdifferent than the first undeformed height. Similarly, the staples in athird longitudinal row of staples can have a third undeformed heightwhich is different that the second undeformed height.

As illustrated in FIG. 15, the staple cartridge 280 comprises two stapledrivers 284 a, two staple drivers 284 b positioned distally with respectto the staple drivers 284 a, two staple drivers 284 c positioneddistally with respect to the staple drivers 284 b, two staple drivers284 d positioned distally with respect to the staple drivers 284 c, twostaple drivers 284 e positioned distally with respect to the stapledrivers 284 d, two staple drivers 284 f positioned distally with respectto the staple drivers 284 e, and two staple drivers 284 g positioneddistally with respect to the staple drivers 284 f which are arranged ina single longitudinal row. Other embodiments are envisioned in which thestaple cartridge 280 does not comprise staple drivers having the samedriver height within the same longitudinal row. In at least one suchembodiment, each staple driver within a longitudinal row has a differentdriver height. Various other embodiments are envisioned which compriseany suitable arrangement of staple drivers in any suitable pattern.

The driver heights of the drivers 284 a-284 g have a linear gradient.The drivers 284 g are taller by a height X than the drivers 284 f, thedrivers 284 f are taller by the height X than the drivers 284 e, thedrivers 284 e are taller by the height X than the drivers 284 d, and soforth. In various alternative embodiments, the driver heights of thedrivers 284 a-284 g can have any other suitable gradient, such as ageometric gradient, for example.

As described above, the drivers 284 a-284 g are illustrated in theirunfired, or unlifted, positions in FIG. 15. As also illustrated in FIG.15, the drivers 284 a-284 g are supported in their unfired positionswithin the staple cartridge 280 such that the tips of the staples 81 arepositioned flush with, or at least nearly flush with, the cartridge deck291. In such instances, the tips of the staples 81 may be positionedflush with the cartridge deck 291, positioned slightly below thecartridge deck 291, and/or positioned slightly above the cartridge deck291 when the staple drivers 284 a-284 g are in their unfired positions.In alternative embodiments, a significant portion of the staples 81 canextend above the cartridge deck 291 when the staple drivers 284 a-284 gare in their unfired positions. In at least one such embodiment, anadjunct material can be positioned over the cartridge deck 291 and thetips of the staples 81 can be embedded in the adjunct material prior tothe staples 81 being lifted by the staple drivers 284 a-284 g. Variousadjunct materials can include a tissue thickness compensator, a buttressmaterial, and/or any suitable layer, for example. The entire disclosureof U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLEFASTENER CARTRIDGE, which issued on Mar. 12, 2013, is incorporated byreference herein.

In certain alternative embodiments, although not illustrated, some ofthe staples 81 may extend above the cartridge deck 291 while some of thestaples 81 may not extend above the cartridge deck 291 when the stapledrivers 284 a-284 g are in their unfired positions. In at least one suchembodiment, the proximal staples 81 are positioned below the cartridgedeck 291 while the distal staples 81 are positioned above the cartridgedeck 291 when the staple drivers 284 a-284 g are in their unfiredpositions. The staple drivers 284 a-284 g can be positioned and arrangedsuch that there is a height gradient between the initial, or unfired,position of the proximal-most staple 81 and the initial, or unfired,position of the distal-most staple 81 of a longitudinal row of stapleswhen the staple drivers 284 a-284 g are in their unfired positions. Thisgradient is a linear gradient; however, alternative embodiments areenvisioned in which the gradient comprises a geometric gradient, forexample.

Further to the above, alternative embodiments are envisioned in whichthe staple drivers 284 a-284 g are stored within the staple cartridge280 such that the bottom drive surfaces thereof are aligned with oneanother when the staple drivers 284 a-284 g are in their unfired, orunlifted, positions. In such instances, the staples 81 are supported atdifferent distances relative to the cartridge deck 291. Such initialpositioning of the staple drivers 284 a-284 g does not affect theforming gaps for the staples 81 discussed above as the forming gaps areset by the final position of the staple drivers 284 a-284 g.

Further to the above, the cartridge deck 291 of the staple cartridge 280comprises a flat, or an at least substantially flat, surface; however,alternative embodiments are envisioned in which the cartridge deck 291is not flat. In at least one embodiment, the distal end of the cartridgedeck 291 is taller than the proximal end of the cartridge deck 291. Inat least one such embodiment, the cartridge deck 291 slopes linearlybetween the proximal end and the distal end. In other embodiments, thecartridge deck 291 slopes geometrically between the proximal end and thedistal end. In various embodiments, the cartridge deck 291 compriseslongitudinal steps having different heights. For instance, the cartridgedeck 291 can comprise a first longitudinal step which is aligned with afirst longitudinal row of staple cavities, a second longitudinal stepwhich is aligned with a second longitudinal row of staple cavities, anda third longitudinal step which is aligned with a third longitudinal rowof staple cavities, for example. The transition between adjacentlongitudinal steps can be a vertical wall or a sloped, or angled, wall,for example.

As discussed above, the staples 81 in the staple cartridge 280 have thesame, or at least substantially the same, unformed height. As alsodiscussed above, the unformed height of the staples in a first row canbe different than the unformed height of the staples in a second row. Incertain embodiments, the staples within a longitudinal row can havedifferent unformed heights. In at least one such embodiment, theproximal-most staple in the row can have a first unformed height and thedistal-most staple in the row can have a second unformed height. In suchan embodiment, the staples between the proximal-most staple and thedistal-most staple can progressively increase in height. The staples canincrease in height between the proximal end and the distal end of theend effector according to a gradient. In at least one instance, thegradient is a linear gradient, for example. In certain instances, thegradient is a geometric gradient, for example.

Embodiments comprising staples having different unformed heights withina row of staples can be used in conjunction with staple drivers havingdifferent driver heights. In at least one embodiment, the proximal-moststaple in a row can be the shortest staple in the row and can be drivenby the shortest staple driver, for example. Moreover, in such anembodiment, the distal-most staple can be the tallest staple in the rowand can be driven by the tallest staple driver, for example. In at leastone embodiment, the shortest staples in a row are paired with theshortest staple drivers and the tallest staples in a row are paired withthe tallest staple drivers, and so forth. In certain other embodiments,the shortest staples in a row are not paired with the shortest stapledrivers and the tallest staples are not paired with the tallest stapledrivers. For instance, the shortest staples can be driven by the talleststaple drivers and the tallest staples can be driven by the shorteststaple drivers, for example. In the end, the staples and the stapledrivers can be paired in any suitable manner to properly fasten thetissue.

As discussed above, the staples 81 in the staple cartridge 280 have thesame, or at least substantially the same, configuration, i.e., aV-shaped configuration, for example. Alternative embodiments areenvisioned in which the staples in a row of staples have differentconfigurations. In at least one embodiment, each of the staples in a rowof staples can have a V-shaped configuration but the angle of the staplelegs that forms the V-shaped configuration can be different for at leastsome of, if not all of, the staples. For instance, the proximal-moststaple in a row of staples can have a narrow V-shaped configuration andthe distal-most staple in the row of staples can have a wide V-shapedconfiguration, for example. In at least one such instance, the angle ofthe staple legs can increase proximally to distally. In other instances,the angle of the staple legs can decrease proximally to distally. Ineither event, the angle of the staple legs can affect the formed heightof the staples and can be selectively used to secure the tissue in adesired manner.

Another unformed configuration of a staple can include a W-shapedstaple, for example. A W-shaped staple can comprise a V-shaped staplewith a portion of the staple base extending upwardly to create asubstantially W-shaped configuration. W-shaped staples are sometimesreferred to as M-shaped or gull-winged staples. The entire disclosure ofU.S. Pat. No. 5,725,554, entitled SURGICAL STAPLE AND STAPLER, whichissued on Mar. 10, 1998, is incorporated by reference herein. In atleast one embodiment, a longitudinal row of staples can include V-shapedstaples at the proximal end of the staple row and W-shaped staples atthe distal end of the staple row, for example. The W-shaped staples canform differently than the V-shaped staples and may be more suitable forstapling tissue in larger forming gaps, for example.

A surgical instrument system 350 is illustrated in FIGS. 16-20. Thesurgical instrument system 350 includes a shaft assembly 360 and an endeffector 370 extending from the shaft assembly 360. In this embodiment,as well as others, the shaft assembly 360 extends from a housing of thetype described above which is configured to be attached to a roboticsurgical system, such as the DAVINCI robotic surgical systemmanufactured by Intuitive Surgical, Inc., for example. Alternatively,the shaft assembly 360 can extend from a handle of a surgical instrumentconfigured to be grasped and operated by a surgeon, for example. Suchhand-held surgical instruments may employ one or more electric motors togenerate the closure and firing motions or the closure and firingmotions may be manually generated by manipulating one or more triggersor actuation arrangements supported on the handle or housing. All ofsuch variations may be effectively employed with the surgical instrumentsystem 350 and may be encompassed by the Claims appended hereto. Furtherdetails of such handles, housings and shaft assemblies are found in thevarious disclosures that have been herein incorporated by reference.Similar to the above-described arrangements, the shaft assembly 360 mayalso comprise at least one articulation joint, such as articulationjoint 364, for example, which is configured to permit the end effector370 to be articulated about at least one axis of rotation. Otherembodiments are envisioned in which the shaft assembly 360 does notcomprise an articulation joint.

Referring primarily to FIG. 16, the end effector 370 comprises a staplecartridge portion 374 and an anvil portion 375. A staple cartridge 380is positioned in the staple cartridge portion 374. The staple cartridge380 is removable from the staple cartridge portion 374 such that it canbe readily replaced with another staple cartridge; however, otherembodiments are envisioned in which the staple cartridge 380 is notreadily replaceable. The anvil portion 375 is movable relative to thestaple cartridge portion 374 about anvil trunnions or pivot pins 376extending from the anvil portion 375. See FIGS. 18, 20 and 22. Forexample, an anvil trunnion 376 extends laterally from each lateral sideof the anvil portion 375 to be movably received within a correspondingopening or slot (not shown) that is formed in the staple cartridgeportion 374. Alternative embodiments are envisioned in which the staplecartridge portion 374 is “rotatable”, “movable” or “pivotable” relativeto the anvil portion 375. The anvil portion 375 is movable between anopen position (FIGS. 16-18) and a fully-closed position (FIGS. 19-22) bya closure drive as described in greater detail further below. Staples,such as staples 381, for example, are removably stored in the staplecartridge 380 and can be ejected from the staple cartridge 380 by afiring drive and deformed against the anvil portion 375, as alsodescribed in greater detail below.

Referring primarily to FIGS. 16-18, the shaft assembly 360 includes arotatable input shaft 361. As described in greater detail further below,the input shaft 361 is utilized to operate the closing drive and thefiring drive. The input shaft 361 is rotatably mounted in a “ground” or“spine” portion 390 of the shaft assembly 360 by one or more bearings391 and comprises a threaded portion 372. See FIG. 16. The closure drivecomprises a closure nut 377 which includes a threaded aperture 362defined therein. The closure nut 377 further comprises closure pins 378extending from opposite sides thereof which are slidably positioned inclosure slots 379 defined in opposite sides of the anvil portion 375.

The threaded aperture 362 of the closure nut 377 is threadably engagedwith the threaded portion 372 of the input shaft 361 such that, when theinput shaft 361 is rotated in a first direction, the closure nut 377 isdisplaced distally toward the end of the end effector 370 in a distaldirection “DD” and, when the input shaft 361 is rotated in a second, oropposite, direction, the closure nut 377 is displaced proximally towardthe housing in a proximal direction “PD”, as illustrated in FIGS. 16-18.The interaction between the closure pins 378 of the closure nut 377 andthe sidewalls of the closure slots 379 prevent the closure nut 377 fromrotating with the input shaft 361 and, as a result, the rotationalmotion of the input shaft 361 is converted to longitudinal translationof the closure nut 377.

In use, the closure nut 377 is advanced distally by the input shaft 361to move the anvil portion 375 between an open position (FIGS. 16-18) andfully-closed positions (FIGS. 19-22). In such instances, the closurepins 378 engage the bottom sidewalls of each closure slot 379 and camthe anvil portion 375 toward the staple cartridge 380. Referringprimarily to FIGS. 19 and 20, it can be observed that in at least theillustrated embodiment, the closure slots 379 have a somewhat arcuateshape. Stated another way, for example, each of the closure slots 379has a proximal slot portion 392 and a distal slot portion 394. The pointor location where the proximal slot portion 392 transitions to thedistal slot portion 394 is referred to herein and the apex 395. SeeFIGS. 20 and 22. When the closure nut 377 is in the proximal-mostposition (e.g., the “beginning position”—FIGS. 16-18), the anvil portion375 is held in the open position. When the closure nut 377 is in thatbeginning position, the closure pins 378 are at the proximal end of theproximal slot portions 392 of each closure slot 379. The mechanicaladvantage attained between the closure pins 378 and the closure slots379 and by virtue of the engagement of the anvil trunnions 376 with thecartridge portion 374 will serve to retain the anvil portion 375 in theopen orientation. When the surgeon desires to close the anvil portion375, the input shaft 361 is rotated in a first direction to drive theclosure nut 377 distally. As the closure pins 378 advance distallythrough the proximal slot portions 392, the anvil portion 375 startscamming closed. Once the closure pins 378 reach the apex 395, the anvilportion 375 is retained in the “fully closed” or “fully clamped”position. Continued rotation of the input shaft 361 will result in thecontinued distal advancement of the closure nut 377. As the closure nut377 continues to move distally, the closure pins 378 continue to advancedistally within the distal slot portions 394 all the while maintainingthe camming or closure force on the anvil portion 375 to positivelyretain it in the closed position. When the surgeon desires to return theanvil portion 375 to the open position, the input shaft 361 is rotatedin the opposite or second direction which drives the closure nut 377proximally back to its proximal-most or beginning position. Because theclosure nut 377 is positively engaged with the input shaft 361 or,stated another way, because the closure nut 377 is threadably engagedwith the threads 372 on the input shaft 361, a positive closure force ismaintained on the anvil portion 375 throughout the closure and firingprocesses. Such arrangement may therefore avoid anvil movement orchatter that may be encountered by prior arrangements wherein theclosure nut is loosely journaled on a portion of the input shaft duringthe firing process.

The input shaft 361 further comprises a distal gear 365 fixedly mountedto the distal end thereof. When the input shaft 361 is rotated in thefirst direction, the distal gear 365 rotates in the first direction and,when the input shaft 361 is rotated in the second direction, the distalgear 365 rotates in the second direction. The firing drive of the endeffector 370 comprises a rotatable firing shaft 371 which is rotatablymounted in the staple cartridge portion 374 by one or more bearings,such as bearing 363, for example. The firing shaft 371 comprises aproximal gear 385, a proximal threaded portion 396 and a distal threadedportion 397. In the illustrated embodiment, the proximal thread portion396 has a first thread “lead” that differs from the second thread leadof the distal thread portion 397 as will be discussed in further detailbelow. The proximal gear 385 of the firing shaft 371 is meshinglyengaged with the distal gear 365 of the input shaft 361 such that theinput shaft 361 can drive the firing shaft 371 when the input shaft 361is rotated. The proximal gear 385 is keyed onto the firing shaft 371such that rotation of the proximal gear 385 results in rotation of thefiring shaft 371.

The firing drive further comprises a firing nut 386 which includes anaxial aperture 389 and a drive member 398. In the illustratedembodiment, the drive member 398 is received within an aperture 399 inthe firing nut 386 and may be biased into driving engagement with thethread portions on the firing shaft 371 by a biasing member or spring(not shown). The firing nut 386 further comprises wedges 383 definedthereon which are configured to slide under the staple drivers and liftthe staples 381 toward the anvil portion 375 to staple tissue positionedbetween the staple cartridge 380 and the anvil portion 375. The firingnut 386 also comprises a cutting member 382 defined thereon which isconfigured to incise the stapled tissue. When the firing nut 386 isthreadably engaged with the distal thread portion 397 of the firingshaft 371 and the input shaft 361 is rotated in the first direction, thefiring nut 386 is displaced distally toward the end of the end effector370 to eject the staples 381 from the staple cartridge 380 and incisethe tissue. When the firing nut 386 is threadably engaged with thedistal threaded portion 397 of the firing shaft 371 and the input shaft361 is rotated in the second direction, the firing nut 386 is displacedproximally. Once the firing nut 386 threadably re-engages with theproximal thread portion 396 on the firing shaft 371, the proximaladvancement of the firing nut 386 slows as it approaches its startingposition—due to the smaller or tighter lead of the proximal threadportion 396.

The above being understood, the surgical instrument system 350 employs arotary driven closure system and firing system that is an improvementover the closure and firing system disclosed in connection with thesurgical instrument system of FIGS. 1-5. As will become further apparentas the present Detailed Description proceeds, the closure and firingsystems of surgical system 350 serve to positively retain the anvilportion 375 in a closed position during the entire firing cycle orstroke in such a manner as to avoid undesirable “chattering” of theanvil portion during firing.

Referring again to FIGS. 16-18, the closure nut 377 is movable from aproximal, “beginning” position to a distal “ending” position during aclamping stroke in order to move the anvil portion 375 from its openposition to its fully-closed position. When the closure nut 377 is inits proximal position, the closure nut 377 is threadably engaged withthe threads 372 defined on the input shaft 361. See FIG. 17. As a resultof the above, the initial rotation of the input shaft 361 in the firstdirection can immediately displace the closure nut 377 distally to beginclosing the anvil portion 375. As the closure nut 377 moves distally,the closure pins 378 move in the proximal portions 392 of the closureslots 379 until they reach the apex 395 at which point the anvil portion375 is fully closed or clamped. Continued rotation of the input shaft361 which is required to distally advance the firing nut 386 will causethe closure nut 377 to continue to advance distally on the input shaft361. Interaction of the closure pins 378 within the distal slot segments394 in the anvil portion 375 will retain the anvil portion 375 in thefully-closed position 375 during the completion of the firing stroke.

Notably, further to the above, the rotation of the input shaft 361 beingutilized to initiate the clamping stroke of the closure nut 377 is beingtransferred to the firing shaft 371 via the meshed gears 365 and 385. Asthe firing shaft 371 is initially rotated, the firing nut 386 is inthreaded engagement with the proximal thread portion 396 on the firingshaft 371 which has a tighter or smaller thread lead than the threadlead of the distal thread portion 397. As a result, when the firing nut386 is in threaded engagement with the proximal thread portion 397, thefiring nut 386 moves slowly through a “neutral firing range” designatedas “NFR” in FIG. 19. When the firing nut 386 is in the neutral firingrange NFR, the firing nut 386 has not advanced distally far enough tostart to incise tissue and fire staples. In various arrangements,however, the firing nut 386 may be configured to slidably engage aportion of the anvil portion 375 to positively retain the anvil portion375 in the closed position and even maintain the spacing of the anvilportion 375 relative to the staple cartridge 380 as the firing nut 386is advanced distally through the end effector 370. For example, thefiring nut 386 may incorporate an I-beam like shape as described invarious disclosures that have been herein incorporated by reference thatis configured to slidably engage the anvil portion 375. However, becausethe closure nut 377 maintains a positive closure force on the anvilportion 375, in at least some embodiments, the firing nut 386 is notconfigured to positively engage the anvil portion 375 so that the firingnut 386 does not apply any closure or clamping motion to the anvilportion.

Referring primarily now to FIGS. 19 and 20, continued rotation of theinput shaft 361 and the firing shaft 371 will drive the firing nut 386to the distal end of the proximal threads 396. Once the drive member 398on the firing nut 386 engages the distal threads, continued rotation ofthe firing shaft 377 will result in the distal advancement of the firingnut 386 through the end effector 370. As a result of the above, theclamping operating mode is completed before the actual staple firingmode is commenced. In addition, the anvil portion 375 is positivelymaintained in the closed position during the entire firing process.Moreover, the surgical instrument system 350 can comprise a sensorsystem, for example, configured to detect when the staple firingoperating mode has been initiated, or is about to be initiated, andpause the electric motor which is driving the input shaft 361. Such asensor system can be configured to detect the position of the closurenut 377, the firing nut 386, and/or the proximal gear 385 for example.In at least one such instance, the electric motor or other driveactuator arrangement can be paused to allow the surgeon to assesswhether they want to proceed with firing the staples into the tissue orre-open the anvil portion 375 to reposition the end effector 370. In atleast one instance, the surgeon can be provided with two switches toselectively operate—a first button which will re-start the electricmotor and proceed with the firing stroke or a second button which willreverse the electric motor to re-open the anvil portion 375, forexample. The first button can be green, for example, and the secondbutton can be red, for example. The first button can include indiciasuch as “GO FORWARD” thereon while the second button can have otherindicia such as “GO BACK” thereon, for example. Such switches can bepositioned on a remote control console and/or the handle of the surgicalinstrument, depending on the circumstances.

As described above, the firing nut 386 is advanced distally to eject thestaples 81 from the staple cartridge 380. The firing nut 386 can beadvanced to the distal end of the end effector 370 to complete a firingstroke, as illustrated in FIGS. 21 and 22. The distal thread portion 397on the firing shaft 371 can be configured such that the drive member 398in the firing nut 386 remains threadably engaged with the distal threads397 on the firing shaft 371 when the firing nut 386 reaches the end ofits firing stroke. In at least one such instance, the firing nut 386,the drive member 398, the wedges 383, and/or the cutting member 382 canchange the state of a switch positioned at the distal end of the endeffector 370 when the firing nut 386 reaches the end of its firingstroke. The switch is in communication with the controller of thesurgical instrument system 350 which can reverse the direction of theelectric motor to rotate the input shaft 361 in its second directionwhen the state of the switch is reversed. When the input shaft 361 isrotated in its second direction, the firing nut 386 is retracted towardits unfired position. In addition to or in lieu of the above, thesurgical instrument 350 can include a switch which can be actuated bythe surgeon to stop and/or reverse the direction of the electric motor.

In use, the anvil portion 375 can be moved away from its fully clampedposition to release the tissue captured between the anvil portion 375and the staple cartridge 380. Moreover, the anvil portion 375 may bemoved between its open position and its closed position to clamp andrelease tissue, as needed, and/or to position the anvil portion 375relative to the staple cartridge 380 such that the end effector 370 canbe inserted into a patient through a trocar, for example. The pausefeature described above can allow the surgical instrument system 350 tobe operated in a first operating range to open and close the anvilportion 375 without firing the staples in the staple cartridge 380and/or incising the tissue.

A portion of another shaft assembly 460 that may be employed inconnection with the various end effectors disclosed above is illustratedin FIGS. 23-28. As can be seen in those Figures, the shaft assembly 460includes a threaded rotary input shaft 461. The threaded rotary inputshaft 461 is configured to receive rotary input motion from a motor thatis located in a handle or housing that is attached to the shaft assembly460 or a portion of a robotic system that is attached to the shaftassembly 460. In alternative embodiments, the rotary input shaft 461 maybe manually actuated by means of a manual trigger or triggers that aresupported on a handle from which the shaft assembly 460 protrudes. Theshaft assembly 460 includes a hollow outer shaft 510 through which therotary input shaft 461 extends. A base member 512 is supported in theouter shaft 510 as shown. The base member 512 may be attached to thehandle or housing as well as the surgical staple portion of the endeffector and effectively function as a “spine” or mechanical “ground”through at least a portion of the shaft assembly 460. The base member512 also serves as a guide for slidably supporting an actuator member469 within the outer shaft 510. For example, as can be seen in FIGS.23-28, the base member 512 comprises an axially extending guide trough514 for receiving a bottom portion 522 of a guide 520 that is attachedto the actuator member 469. When viewed from an end, the guide 520roughly resembles a “T-shape”. As shown, one side of the base member 512comprises a lateral guide slot 516 for receiving a lateral arm portion524 of the guide 520.

As shown in FIGS. 23-28, the actuator member 469 comprises a closure nutassembly 477 that is configured to impart opening and closing motions toan anvil portion in the manner described herein. The closure nutassembly 477 comprises a “clam-shell” arrangement comprising a firstclosure nut segment 530 and a second closure nut segment 550 that arepivotably supported on a pivot rod or pivot member 560 that is attachedto the guide 520. Such arrangement enables the closure nut segments 530,550 to pivot from an engaged configuration (FIGS. 23-26) to a disengagedconfiguration (FIGS. 27 and 28). The first closure nut segment 530includes a first thread engagement member 532 and the second closure nutsegment 550 includes a second thread engagement member 552. When theclosure nut assembly 477 is in the engaged configuration, the firstthread engagement member 532 and the second thread engagement member 552engage the input shaft 461 such that rotation of the input shaft 461results in the axial movement of the closure nut assembly 477. It willbe appreciated that one, and preferably two, laterally extending pivotpins are attached to a structure that extends from the guide 520 and orthe pivot member 560 and are received in the corresponding anvil slotsin the manners described above. Thus, axial movement of the closure nutassembly 477 will result in the opening and closing of the anvil portionin the manners described above.

Referring to FIGS. 23 and 24, the selective movement of the first andsecond closure nut segments 530 and 550 between the engaged anddisengaged configurations is controlled by a solenoid or switchingmember 570. In the illustrated arrangement, for example, the solenoid570 includes a solenoid body portion 572 that is attached to the firstclosure nut segment 530. A solenoid rod 574 is movably supported withinthe body portion 572 and the first closure nut segment 530 to be movablyreceived in the second closure nut segment 550. As can be seen in FIGS.23-28, the solenoid rod 574 has a head 576 that is movably received inU-slot 556 in the second closure nut portion 550.

Still referring to FIGS. 23 and 24, a pair of base contacts 518 arelocated in the base member 512 and open into the guide trough 514 tofacilitate sliding electrical contact with solenoid contacts 578. Thebase contacts 518 are electrically coupled to a controller by leads 519that extend through the base member 512 back to the handle, housing orother portion for the robotic system whichever the case may be. Forexample, the controller may cooperate with a trigger or other switchingmechanism that can be used to control the supply of electrical currentto the base contacts 518 and ultimately to the solenoid 570 throughleads 579 that extend between the solenoid 570 and the solenoid contacts578. As can be seen in FIG. 23, in at least one arrangement, the rangeof axial movement of the closure nut assembly 477 may be defined by thelength “L” of the base contacts 518, for example. In one arrangement,the solenoid 570, in a de-energized state, is biased into the engagedposition wherein the solenoid rod 572 is retained in the retracted stateshown in FIGS. 23-26. When the solenoid 570 is energized, the solenoidrod 572 is laterally displaced toward the second closure segment 550 tothereby pivot the closure nut assembly 477 to the disengagedconfiguration (FIGS. 27 and 28). In alternative arrangements, thesolenoid may be biased into the disengaged configuration when thesolenoid is de-energized and then is moved to the engaged configurationwhen the solenoid is energized. In still other arrangements, thesolenoid must be positively actuated between the engaged and disengagedconfigurations (i.e., no biasing member is employed in the solenoid tobias the solenoid into one of the described configurations).

When the closure nut assembly 477 is in the disengaged configuration,rotation of the input shaft 461 will not be transferred to the closurenut assembly 477. Thus, in one arrangement, the closure nut 477 may beconfigured in the engaged position to close the anvil portion. Once theanvil portion has been moved to the closed position (which may bedetected by sensors in the anvil portion and or the surgical stapleportion), the controller may then de-energize the motor as well as thesolenoid which will to move the closure nut assembly 477 to thedisengaged configuration. At that point, the controller may once againactivate the motor to rotate the input shaft 461 to commence the firingoperation in the above-described manner without actuating or axiallymoving the closure nut assembly 477.

The illustrated surgical instrument system depicted in FIGS. 23-28 alsoemploys a locking system 580 to positively lock the closure nut assemblyin position (e.g., prevent further axial movement) when it is in thedistal-most disengaged orientation. As can be seen in those Figures, thelocking system 580 comprises a movable lock linkage 582 that includes adistal link 583 that is pivotally pinned to a proximal link 586 by anupstanding central lock pin 587. A proximal end 588 of the proximal link586 is pivotally pinned to the base member 512 by a proximal pin 589.The distal end 584 of the distal link 583 is pivotally pinned to theguide 520 by a pin 585. Thus, the lock linkage 582 moves between acollapsed configuration (FIG. 23), an aligned “pre-locked” configuration(FIGS. 25 and 26) and a locked configuration (FIGS. 27 and 28).

As can be seen in FIGS. 23-28, the locking system 580 also comprises alock arm 590 that is attached to or otherwise protrudes from the closurenut assembly 477 and, in the illustrated embodiment, from the firstclosure nut segment 530. The lock arm 590 includes a lock pin hole 592that is configured to retainingly engage and receive a portion of thelock pin 587 therein. As can be seen in FIGS. 24, 26 and 28, the bottomend of the lock pin hole 592 includes a chamfer or tapered portion 594to facilitate entry of the lock pin 587 therein.

One method of using the closure nut assembly 477 will now be described.When the clinician desires to close the anvil portion, the input shaft461 is rotated in a first direction. This rotary motion may be appliedto the input shaft 461 by an electric motor, a robotic system or amanually actuatable closure system that is configured to generate rotarymotions upon ratcheting or other form of manipulation of a closuretrigger or the like. When in that position, the solenoid is biased intothe engaged position (by a spring or other biasing arrangement) andremains un-energized. Rotation of the input shaft 461 causes the closurenut assembly 477 to move distally. As was discussed above, the distalmovement of the closure nut assembly 477 will result in the closure ofthe anvil portion by means of the camming interaction between theclosure pins and the anvil slots provided in the anvil mounting portion.If the clinician desires to reopen the anvil portion (to reposition theend effector on the desired target tissue or for some other reason), theclinician simply causes the motor or other actuation mechanism toreverse the direction in which the input shaft is rotated (seconddirection). In any event, once the closure nut assembly 477 has beendistally advanced to the position in which the anvil portion is “fullyclosed” (FIG. 25), the application of the rotary motion to the inputshaft 461 is discontinued. This may be manually accomplished by theclinician or, if sensors are employed to detect the position of theclosure nut assembly 477 and/or the position of the anvil portion, thecontrol system may “automatically” discontinue application of power tothe motor. As can be seen in FIG. 25, when in that fully-closedposition, the movable lock linkage is configured in a pre-lockedposition wherein the end of the lock pin 587 is aligned with the lockhole 592 in the lock arm 590. When in this position, if the cliniciandesires to open the anvil portion, the motor is simply re-energized torotate the input shaft 461 in the second direction. If, however, theclinician does not want to reopen the anvil portion and desires tocommence the firing stage, the clinician energizes the solenoid to movethe closure nut segments to the disengaged configuration (FIGS. 27 and28). As can be seen in those Figures, when the first closure nut segment530 is pivoted in the direction of the closure linkage 580, the end ofthe closure pin 587 enters the hole 592 in the lock arm 590 topositively retain the closure nut assembly 477 in the disengagedposition as well as preventing the closure nut assembly 477 from movingaxially during the firing sequence. When in that position, as can beseen in FIG. the links 586 and 584 are in a “buckled” configuration andmay abut a portion of the base member and/or inner wall of the outershaft 510 to add further locking resistance to the closure nut assembly477. In another arrangement, the control system may “automatically”energize the solenoid 570 when the switching system confirmed that theclosure nut assembly 477 and/or the anvil portion has attained the fullyclosed position. In such case, the closure nut assembly 477 isautomatically moved to the disengaged and locked position. Once thefiring nut has completed the firing stroke and returned to the startposition, switches may be employed to detect its status/position andcause the control system to de-energize the solenoid to permit it to bebiased back into the engaged position. Other solenoid arrangements maynot include a biasing member to bias the solenoid back to its startingposition, but instead require a second signal to move it back to thestarting position. In those cases, the control system would send thesecond signal to the solenoid to cause the closure nut assembly toreengage the input shaft. Thereafter, the control system mayautomatically energize the motor to rotate the input shaft in the seconddirection to return the closure nut assembly to its beginning positionand thereby return the anvil portion to the open position.

The surgical instrument systems described herein are motivated by anelectric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The surgical instrument systems described herein are motivated by one ormore electric motors; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example.

EXAMPLES Example 1

A surgical instrument, comprising a rotary input shaft and means forselectively applying rotary input motions to the rotary input shaft. Thesurgical instrument further comprises a surgical end effector thatcomprises a first jaw and a second jaw that is selectively movablerelative to the first jaw between an open and closed position. A firingshaft operably interfaces with the rotary input shaft such that thefiring shaft rotates in response to rotation of the rotary input shaft.A firing member is movably supported in one of the first and second jawsfor selective axial movement between start and end positions in responseto rotation of the firing shaft. A closure member is located in threadedengagement with the rotary input shaft such that rotation of the rotaryinput shaft in a first direction causes the closure member to move thesecond jaw to the closed position. The closure member remains inthreaded engagement with the rotary input shaft to retain the second jawin the closed position while continued rotation of the rotary inputshaft in the first direction drives the firing member from the startposition to the end position.

Example 2

The surgical instrument of Example 1, wherein the first jaw comprises asurgical staple cartridge and the second jaw comprises an anvil, andwherein the firing member comprises a tissue cutting surface and a wedgefor driving surgical staples from the surgical staple cartridge intoforming contact with the anvil.

Example 3

The surgical instrument of Examples 1 or 2, wherein the input shaft andthe firing shaft are not coaxially aligned.

Example 4

The surgical instrument of Examples 1, 2 or 3, wherein the firing shaftcomprises a proximal set of threads having a first lead and a distal setof threads having a second lead that differs from the first lead.

Example 5

The surgical instrument of Example 4, wherein the second lead is greaterthan the first lead.

Example 6

The surgical instrument of Examples 2, 3, 4 or 5, wherein the firingmember is configured to engage the anvil as the firing member movesbetween the start and end positions.

Example 7

The surgical instrument of Examples 1, 2, 3, 4, 5 or 6, wherein thefiring member is configured to space the first and second jaws at adesired distance from each other as the firing member moves between thestart and end positions.

Example 8

The surgical instrument of Examples 1, 2, 3, 4, 5, 6 or 7, wherein themeans for selectively applying comprises an electric motor.

Example 9

The surgical instrument of Examples 1, 2, 3, 4, 5, 6 or 7, wherein themeans for selectively applying comprises a robotic system.

Example 10

A surgical instrument, comprising an elongate shaft assembly thatcomprises an input shaft. The surgical instrument further comprises asurgical end effector that comprises a staple cartridge portion and ananvil that is supported for selective movement relative to the staplecartridge portion. A firing shaft is operably supported by the staplecartridge portion. The firing shaft operably interfaces with the inputshaft such that the firing shaft is actuated upon application of anactuation motion to the input shaft. A firing member is movablysupported in the staple cartridge portion for selective axial movementbetween start and end positions in response to the actuation of thefiring shaft. A closure member operably interfaces with the input shaftand is configured to axially move from a beginning position to an endingposition. A clamped position is located intermediate the beginning andending positions and corresponds to a position wherein the closuremember retains the anvil in a fully closed position. Further actuationof the input shaft after the closure member has attained the clampingposition causes the firing member to move from the start to the endposition and the closure member to move from the clamping position tothe ending position while retaining the anvil in the fully closedposition.

Example 11

The surgical instrument of Example 10, wherein the closure memberincludes at least one pivot pin that is received in a corresponding pinslot in a mounting portion of the anvil portion. Each pin slot comprisesa proximal slot portion that corresponds to the beginning position ofthe closure member. A distal slot portion joins the proximal slotportion at an apex point that corresponds to the clamped position suchthat the distal slot portion is not axially aligned with the proximalslot portion.

Example 12

The surgical instrument of Examples 10 or 11, wherein the firing shaftis rotatably actuated by applying the actuation motion to the inputshaft and wherein the firing member is threadably engaged with thefiring shaft.

Example 13

The surgical instrument of Examples 10, 11 or 12, wherein the inputshaft and the firing shaft are not coaxially aligned.

Example 14

The surgical instrument of Examples 10, 11, 12 or 13, wherein the firingshaft comprises a proximal set of threads having a first lead and adistal set of threads having a second lead that differs from the firstlead.

Example 15

The surgical instrument of Example 14, wherein the second lead isgreater than the first lead.

Example 16

The surgical instrument of Examples 10, 11, 12, 13, 14 or 15, whereinthe closure member is threadably engaged with the input shaft.

Example 17

The surgical instrument of Examples 10, 11, 12, 13, 14, 15 or 16,further comprising means for applying the actuation motion to the inputshaft.

Example 18

The surgical instrument of Example 17, wherein the means for applyingcomprises an electric motor.

Example 19

The surgical instrument of Example 17, wherein the means for applyingcomprises a robotic system.

Example 20

A surgical instrument system, comprising a housing and a motor that isoperably supported by the housing and configured to generate rotarymotions. A rotary input shaft is configured to receive the rotarymotions from the motor. The surgical instrument system further comprisesa surgical end effector that comprises a staple cartridge portion and ananvil that is supported for selective movement relative to the staplecartridge portion. A firing shaft is operably supported by the staplecartridge portion. The firing shaft operably interfaces with the inputshaft such that the firing shaft is actuated upon application of therotary motions to the rotary input shaft. The surgical end effectorfurther comprises a firing nut that comprises a tissue cutting surfaceand a wedge. The firing nut is in threaded engagement with a threadedsection of the firing shaft that comprises a proximal thread segmentthat comprises a first thread lead and a distal thread segment thatcomprises a second thread lead that is greater than the first threadlead. The surgical instrument system further comprises a closure nutthat is in threaded engagement with the rotary input shaft such thatrotation of the rotary input shaft in a first direction causes theclosure nut to move the anvil from an open to a closed position. Theclosure nut remains in threaded engagement with the rotary input shaftto retain the anvil in the closed position while continued rotation ofthe rotary input shaft in the first direction drives the firing nut fromthreaded engagement with the proximal thread segment to threadedengagement with the distal thread segment.

Example 21

A surgical instrument, comprising a surgical end effector and a threadedrotary input shaft. An actuator member is in operable engagement withthe surgical end effector and is in selective threaded engagement withthe threaded rotary input shaft such that when the actuator member is inan engaged configuration, the actuator member is in threaded engagementwith the threaded rotary input shaft such that rotation of the threadedrotary input shaft causes the actuator member to move axially to impartan actuation motion to the surgical end effector and when the actuatormember is in a disengaged configuration, rotation of the threaded rotaryinput shaft will not be imparted to the actuator member. The surgicalinstrument further comprises means for selectively moving the actuatorbetween the engaged and disengaged configurations and a locking systemfor preventing axial movement of the actuator member when the actuatormember is in the disengaged configuration.

Example 22

The surgical instrument of Example 21, wherein the surgical end effectorcomprises a first jaw and a second jaw that is selectively movablerelative to the first jaw between an open and closed position. Theactuator member comprises a closure member that is in operableengagement with the second jaw such that when the closure member is inthe engaged configuration, rotation of the threaded rotary input shaftcauses the closure member to move the second jaw from the open to theclosed position and when the threaded rotary input shaft is rotated in asecond direction, the closure member moves the second jaw from theclosed position to the open position.

Example 23

The surgical instrument of Example 22, wherein the first jaw comprises asurgical staple cartridge and the second jaw comprises an anvil.

Example 24

The surgical instrument of Examples 21, 22 or 23, wherein the actuatormember comprises a first actuator segment that is supported for axialtravel relative to the threaded rotary input shaft and comprises a firstthread engagement portion. A second actuator segment is supported foraxial travel relative to the threaded rotary input shaft and comprisinga second thread engagement portion. The first and second actuatorsegments are selectively movable relative to each other by the means forselectively moving between the engaged configuration wherein the firstand second thread engagement portions cooperate to threadably engage thethreaded rotary input shaft and the disengaged configuration wherein thefirst and second thread engagement portions do not threadably engage thethreaded rotary input shaft.

Example 25

The surgical instrument of Example 24, wherein the first actuatorsegment and the second actuator segment are pivotally coupled together,and wherein the means for selectively moving comprises a solenoid.

Example 26

The surgical instrument of Examples 24 or 25, wherein the locking systemcomprises a locking pin that is movably supported relative to theactuator member and a lock member that protrudes from the first actuatorsegment and is configured to lockingly engage the locking pin when thefirst actuator segment is in the disengaged configuration.

Example 27

The surgical instrument of Examples 21, 22, 23, 24, 25 or 26, whereinthe surgical instrument further comprises means for selectively applyingrotary input motions to the threaded rotary input shaft.

Example 28

The surgical instrument of Example 27, wherein the means for selectivelyapplying comprises an electric motor.

Example 29

The surgical instrument of Examples 21, 22, 23, 24, 25, 26, 27 or 28,wherein the means for selectively applying comprises a robotic system.

Example 30

The surgical instrument of Examples 22, 23, 24, 25, 26, 27, 28, 29further comprising a firing shaft that operably interfaces with thethreaded rotary input shaft such that the firing shaft rotates inresponse to rotation of the threaded rotary input shaft. A firing memberis movably supported in one of the first and second jaws for selectiveaxial movement between start and end positions in response to rotationof the firing shaft.

Example 31

The surgical instrument of Example 30, wherein the first jaw comprises asurgical staple cartridge and the second jaw comprises an anvil, andwherein the firing member comprises a tissue cutting surface and a wedgefor driving surgical staples from the surgical staple cartridge intoforming contact with the anvil.

Example 32

A surgical instrument comprising a rotary input shaft and a surgical endeffector. The surgical end effector comprises a first jaw and a secondjaw that is selectively movable relative to the first jaw between anopen and closed position. The surgical instrument further comprises aclosure member that is in operable engagement with the second jaw and inselective operable engagement with the rotary input shaft such that whenthe closure member is in an engaged configuration with the rotary inputshaft, rotation of the rotary input shaft causes the closure member toimpart an actuation motion to the second jaw and when the closure memberis in a disengaged configuration, rotation of the input shaft will notbe imparted to the closure member. The surgical instrument furthercomprises a switch for selectively moving the closure member between theengaged and disengaged configuration and a locking system for preventingaxial movement of the closure member when the closure member is in thedisengaged configuration.

Example 33

The surgical instrument of Example 32, wherein the first jaw comprises asurgical staple cartridge and the second jaw comprises an anvil.

Example 34

The surgical instrument of Examples 32 or 33, wherein the closure membercomprises a first closure nut segment that is supported for axial travelrelative to the rotary input shaft and comprises a first threadengagement portion. A second closure nut segment is supported for axialtravel relative to the rotary input shaft and comprises a second threadengagement portion. The first and second closure nut segments areselectively movable relative to each other by the switch between theengaged configuration wherein the first and second thread engagementportions cooperate to threadably engage the rotary input shaft and thedisengaged configuration wherein the first and second thread engagementportions do not threadably engage the rotary input shaft.

Example 35

The surgical instrument of Example 34, wherein the first closure nutsegment and the second closure nut segment are pivotally coupledtogether, and wherein the switch comprises a solenoid.

Example 36

The surgical instrument of Examples 32, 33, 34 or 35, wherein thelocking system comprises a locking pin supported relative to the closuremember and a lock member that protrudes from a portion of the firstclosure member and is configured to lockingly engage the locking pinwhen the closure member is in the disengaged configuration.

Example 37

The surgical instrument of Example 36, wherein the locking pin ismovably supported relative to the closure member.

Example 38

The surgical instrument of Example 37, wherein the locking pin issupported on a linkage that is movably coupled to the closure member.

Example 39

The surgical instrument of Examples 32, 33, 34, 35, 36, 37 or 38 furthercomprising a firing shaft that operably interfaces with the rotary inputshaft such that the firing shaft rotates in response to rotation of therotary input shaft and a firing member that is movably supported in oneof the first and second jaws for selective axial movement between startand end positions in response to rotation of the firing shaft.

Example 40

A surgical instrument system, comprising a surgical end effector and athreaded rotary input shaft. The surgical instrument further comprises aclam-shell actuator member that is supported in operable engagement withthe surgical end effector and is selectively movable between a firstclosed configuration wherein the actuator member is in threadedengagement with the rotary input shaft and a second open configurationwherein the actuator member is not in threaded engagement with thethreaded rotary input shaft.

Example 41

A staple cartridge for use with a surgical stapler including an anvil,the staple cartridge comprising a cartridge body including a proximalend, a distal end, a deck, a longitudinal slot defined in the deck, anda longitudinal row of staple cavities. The staple cartridge furthercomprises staples removably stored in the longitudinal row of staplecavities, a longitudinal row of staple drivers movable between anunfired position and a fired position to drive the staples toward theanvil, and a firing system movable toward the distal end to sequentiallymove the staple drivers between their unfired position and their firedposition. The longitudinal row of staple drivers comprises a firststaple driver comprising a first bottom drive surface configured to bedriven by the firing system and a first support surface configured todrive a first staple toward the anvil, wherein a first driver distanceis defined between the first bottom drive surface and the first supportsurface and a second staple driver comprising a second bottom drivesurface configured to be driven by the firing system and a secondsupport surface configured to drive a second staple toward the anvil,wherein a second driver distance is defined between the second bottomdrive surface and the second support surface, and wherein the seconddriver distance is different than the first driver distance.

Example 42

The staple cartridge of Example 41, wherein the first staple driver ispositioned proximally with respect to the second staple driver, andwherein the first driver distance is shorter than the second driverdistance.

Example 43

The staple cartridge of Examples 41 or 42, wherein the first supportsurface comprises a first cradle configured to receive a portion of thefirst staple therein, and wherein the second support surface comprises asecond cradle configured to receive a portion of the second stapletherein.

Example 44

The staple cartridge of Examples 41, 42, or 43, wherein the first stapledriver is not connected to the second staple driver.

Example 45

The staple cartridge of Examples 41, 42, or 43, wherein the first stapledriver is connected to the second staple driver.

Example 46

The staple cartridge of Examples 41, 42, 43, 44, or 45, wherein thelongitudinal row of staple drivers comprises a third staple driverpositioned distally with respect to the second staple driver, whereinthe third staple driver comprises a third bottom drive surfaceconfigured to be driven by the firing system and a third support surfaceconfigured to drive a third the staple toward the anvil, wherein a thirddriver distance is defined between the third bottom drive surface andthe third support surface, and wherein the second driver distance isshorter than the third driver distance.

Example 47

The staple cartridge of Examples 41, 42, 43, 44, 45, or 46, wherein thefirst driver height, the second driver height, and the third driverheight increase in height according to a linear gradient.

Example 48

The staple cartridge of Examples 41, 42, 43, 44, 45, or 46, wherein thefirst driver height, the second driver height, and the third driverheight increase in height according to a geometric gradient.

Example 49

The staple cartridge of Examples 41, 42, 43, 44, 45, 46, 47, or 48,wherein the first longitudinal row of staple drivers are configured todrive a first group of the staples, wherein the first staple and thesecond staple are part of the first group of staples, wherein the staplecartridge further comprises a second longitudinal row of staple driversconfigured to drive a second group of the staples, wherein the firstgroup of staples are defined by a first undeformed height and the secondgroup of staples are defined by a second undeformed height, and whereinthe first undeformed height is different than the second undeformedheight.

Example 50

The staple cartridge of Example 49, wherein the deck comprises a firststep aligned with the first group of staples and a second step alignedwith the second group of staples, wherein the first step is defined by afirst height, wherein the second step is defined by a second height, andwherein the first height is different than the second height.

Example 51

The staple cartridge of Examples 41, 42, 43, 44, 45, 46, 47, 48, or 49,wherein the deck is flat.

Example 52

The staple cartridge of Examples 41, 42, 43, 44, 45, 46, 47, 48, 49, 50or 51, wherein the staples are positioned below the deck when the stapledrivers are in their unfired position.

Example 53

The staple cartridge of Examples 41, 42, 43, 44, 45, 46, 47, 48, 49, 50,51, or 52 further comprising a piece of adjunct material positioned overthe deck.

Example 54

The staple cartridge of Example 53, wherein the adjunct materialcomprises a tissue thickness compensator.

Example 55

The staple cartridge of Examples 41, 42, 43, 44, 45, 46, 47, 48, 49, 50or 51, wherein the first staple is positioned below the deck and thesecond staple is partially positioned above the deck when the stapledrivers are in their unfired position, wherein the staple cartridgefurther comprises an adjunct material positioned over the deck, andwherein the second staple is partially embedded in the adjunct materialwhen the staple drivers are in their unfired position.

Example 56

The staple cartridge of Example 55, wherein the adjunct comprises atissue thickness compensator.

Example 57

The staple cartridge of Examples 41, 42, 43, 44, 45, 46, 47, 48, 49, 50or 51, wherein the staples driven by the longitudinal row of stapledrivers are stored within the cartridge body such that they arepositioned at the same distance relative to the deck when the stapledrivers are in their unfired position.

Example 58

The staple cartridge of Examples 41, 42, 43, 44, 45, 46, 47, 48, 49, 50or 51, wherein the staples driven by the longitudinal row of stapledrivers are stored within the cartridge body such that they are notpositioned at the same distance relative to the deck when the stapledrivers are in their unfired position.

Example 59

A staple cartridge for use with a surgical stapler including an anvil,the staple cartridge comprising a cartridge body including a proximalend, a distal end, a deck, a longitudinal slot defined in the deck, anda longitudinal row of staple cavities. The staple cartridge furthercomprises staples removably stored in the longitudinal row of staplecavities, a longitudinal row of staple drivers movable between anunfired position and a fired position to drive the staples toward theanvil, a firing system movable toward the distal end to sequentiallymove the staple drivers between their unfired position their firedposition, and means for driving the staples to different distancesrelative to the deck.

Example 60

An end effector for use with a surgical system, the end effectorcomprising a fastener cartridge including a distal end, a deck, and alongitudinal row of fastener cavities. The end effector furthercomprises fasteners removably stored in the longitudinal row of fastenercavities, a forming jaw, a longitudinal row of fastener drivers movablebetween an unfired position and a fired position to drive the fastenerstoward the forming jaw, and a firing system movable toward the distalend to sequentially move the fastener drivers between their unfiredposition and their fired position. The longitudinal row of fastenerdrivers comprises a first fastener driver comprising a first bottomdrive surface configured to be driven by the firing system and a firstsupport surface configured to drive a first fastener toward the anvil,wherein a first driver distance is defined between the first bottomdrive surface and the first support surface, and a second fastenerdriver comprising a second bottom drive surface configured to be drivenby the firing system and a second support surface configured to drive asecond fastener toward the anvil, wherein a second driver distance isdefined between the second bottom drive surface and the second supportsurface, and wherein the second driver distance is different than thefirst driver distance.

The entire disclosures of:

-   -   U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC        DEVICE, which issued on Apr. 4, 1995;    -   U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT        HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which        issued on Feb. 21, 2006;    -   U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING        AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which        issued on Sep. 9, 2008;    -   U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL        INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS,        which issued on Dec. 16, 2008;    -   U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING AN        ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;    -   U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS,        which issued on Jul. 13, 2010;    -   U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE        IMPLANTABLE FASTENER CARTRIDGE, which issued on Mar. 12, 2013;    -   U.S. patent application Ser. No. 11/343,803, entitled SURGICAL        INSTRUMENT HAVING RECORDING CAPABILITIES; now U.S. Pat. No.        7,845,537;    -   U.S. patent application Ser. No. 12/031,573, entitled SURGICAL        CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed        Feb. 14, 2008;    -   U.S. patent application Ser. No. 12/031,873, entitled END        EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed        Feb. 15, 2008, now U.S. Pat. No. 7,980,443;    -   U.S. patent application Ser. No. 12/235,782, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No.        8,210,411;    -   U.S. patent application Ser. No. 12/249,117, entitled POWERED        SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY        RETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045;    -   U.S. patent application Ser. No. 12/647,100, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR        DIRECTIONAL CONTROL ASSEMBLY, filed Dec. 24, 2009; now U.S. Pat.        No. 8,220,688;    -   U.S. patent application Ser. No. 12/893,461, entitled STAPLE        CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;    -   U.S. patent application Ser. No. 13/036,647, entitled SURGICAL        STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No.        8,561,870;    -   U.S. patent application Ser. No. 13/118,241, entitled SURGICAL        STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT        ARRANGEMENTS, now U.S. Patent Application Publication No.        2012/0298719;    -   U.S. patent application Ser. No. 13/524,049, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE,        filed on Jun. 15, 2012; now U.S. Patent Application Publication        No. 2013/0334278;    -   U.S. patent application Ser. No. 13/800,025, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Patent Application Publication No. 2014/0263551;    -   U.S. patent application Ser. No. 13/800,067, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Patent Application Publication No. 2014/0263552;    -   U.S. Patent Application Publication No. 2007/0175955, entitled        SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER        LOCKING MECHANISM, filed Jan. 31, 2006; and    -   U.S. Patent Application Publication No. 2010/0264194, entitled        SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR,        filed Apr. 22, 2010, now U.S. Pat. No. 8,308,040, are hereby        incorporated by reference herein.

Although the various embodiments of the devices have been describedherein in connection with certain disclosed embodiments, manymodifications and variations to those embodiments may be implemented.Also, where materials are disclosed for certain components, othermaterials may be used. Furthermore, according to various embodiments, asingle component may be replaced by multiple components, and multiplecomponents may be replaced by a single component, to perform a givenfunction or functions. The foregoing description and following claimsare intended to cover all such modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

By way of example only, aspects described herein may be processed beforesurgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device also may be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, plasma peroxide, or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A staple cartridge for use with a surgicalstapler including an anvil, said staple cartridge comprising: acartridge body, comprising: a proximal end; a distal end; a deck; alongitudinal slot defined in said deck; and a longitudinal row of staplecavities; staples removably stored in said longitudinal row of staplecavities; a longitudinal row of staple drivers movable between anunfired position and a fired position to drive said staples toward theanvil; a firing system movable toward said distal end to sequentiallymove said staple drivers between said unfired position and said firedposition, wherein said longitudinal row of staple drivers comprises: afirst staple driver comprising a first bottom drive surface configuredto be driven by said firing system and a first support surfaceconfigured to drive a first said staple toward the anvil, wherein afirst driver distance is defined between said first bottom drive surfaceand said first support surface; and a second staple driver comprising asecond bottom drive surface configured to be driven by said firingsystem and a second support surface configured to drive a second saidstaple toward the anvil, wherein a second driver distance is definedbetween said second bottom drive surface and said second supportsurface, and wherein said second driver distance is different than saidfirst driver distance.
 2. The staple cartridge of claim 1, wherein saidfirst staple driver is positioned proximally with respect to said secondstaple driver, and wherein said first driver distance is shorter thansaid second driver distance.
 3. The staple cartridge of claim 1, whereinsaid first support surface comprises a first cradle configured toreceive a portion of said first staple therein, and wherein said secondsupport surface comprises a second cradle configured to receive aportion of said second staple therein.
 4. The staple cartridge of claim1, wherein said first staple driver is not connected to said secondstaple driver.
 5. The staple cartridge of claim 1, wherein said firststaple driver is connected to said second staple driver.
 6. The staplecartridge of claim 1, wherein said longitudinal row of staple driverscomprises a third staple driver positioned distally with respect to saidsecond staple driver, wherein said third staple driver comprises a thirdbottom drive surface configured to be driven by said firing system and athird support surface configured to drive a third said staple toward theanvil, wherein a third driver distance is defined between said thirdbottom drive surface and said third support surface, and wherein saidsecond driver distance is shorter than said third driver distance. 7.The staple cartridge of claim 1, wherein said first driver height, saidsecond driver height, and said third driver height increase in heightaccording to a linear gradient.
 8. The staple cartridge of claim 1,wherein said first driver height, said second driver height, and saidthird driver height increase in height according to a geometricgradient.
 9. The staple cartridge of claim 1, wherein said firstlongitudinal row of staple drivers are configured to drive a first groupof said staples, wherein said first staple and said second staple arepart of said first group of staples, wherein said staple cartridgefurther comprises a second longitudinal row of staple drivers configuredto drive a second group of said staples, wherein said first group ofstaples are defined by a first undeformed height and said second groupof staples are defined by a second undeformed height, and wherein saidfirst undeformed height is different than said second undeformed height.10. The staple cartridge of claim 9, wherein said deck comprises a firststep aligned with said first group of staples and a second step alignedwith said second group of staples, wherein said first step is defined bya first height, wherein said second step is defined by a second height,and wherein said first height is different than said second height. 11.The staple cartridge of claim 1, wherein said deck is flat.
 12. Thestaple cartridge of claim 1, wherein said staples are positioned belowsaid deck when said staple drivers are in said unfired position.
 13. Thestaple cartridge of claim 12, further comprising a piece of adjunctmaterial positioned over said deck.
 14. The staple cartridge of claim13, wherein said adjunct material comprises a tissue thicknesscompensator.
 15. The staple cartridge of claim 1, wherein said firststaple is positioned below said deck and said second staple is partiallypositioned above said deck when said staple drivers are in said unfiredposition, wherein said staple cartridge further comprises an adjunctmaterial positioned over said deck, and wherein said second staple ispartially embedded in said adjunct material when said staple drivers arein said unfired position.
 16. The staple cartridge of claim 15, whereinsaid adjunct comprises a tissue thickness compensator.
 17. The staplecartridge of claim 1, wherein said staples driven by said longitudinalrow of staple drivers are stored within said cartridge body such thatthey are positioned at the same distance relative to said deck when saidstaple drivers are in said unfired position.
 18. The staple cartridge ofclaim 1, wherein said staples driven by said longitudinal row of stapledrivers are stored within said cartridge body such that they are notpositioned at the same distance relative to said deck when said stapledrivers are in said unfired position.
 19. A staple cartridge for usewith a surgical stapler including an anvil, said staple cartridgecomprising: a cartridge body, comprising: a proximal end; a distal end;a deck; a longitudinal slot defined in said deck; and a longitudinal rowof staple cavities; staples removably stored in said longitudinal row ofstaple cavities; a longitudinal row of staple drivers movable between anunfired position and a fired position to drive said staples toward theanvil; a firing system movable toward said distal end to sequentiallymove said staple drivers between said unfired position and said firedposition; and means for driving said staples to different distancesrelative to said deck.
 20. An end effector for use with a surgicalsystem, said end effector comprising: a fastener cartridge, comprising:a distal end; a deck; and a longitudinal row of fastener cavities;fasteners removably stored in said longitudinal row of fastenercavities; a forming jaw; a longitudinal row of fastener drivers movablebetween an unfired position and a fired position to drive said fastenerstoward said forming jaw; a firing system movable toward said distal endto sequentially move said fastener drivers between said unfired positionand said fired position, wherein said longitudinal row of fastenerdrivers comprises: a first fastener driver comprising a first bottomdrive surface configured to be driven by said firing system and a firstsupport surface configured to drive a first said fastener toward theanvil, wherein a first driver distance is defined between said firstbottom drive surface and said first support surface; and a secondfastener driver comprising a second bottom drive surface configured tobe driven by said firing system and a second support surface configuredto drive a second said fastener toward the anvil, wherein a seconddriver distance is defined between said second bottom drive surface andsaid second support surface, and wherein said second driver distance isdifferent than said first driver distance.